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Owners Manual

Operator/Installation

Controller

PowerCommand1302

English
Original Instructions 6-2014 9000661 (Issue 10)
Intentionally Left Blank

58
Table of Contents

SECTION TITLE PAGE


Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Connector Seal Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Kit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Additional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
1302 Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Current Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
1302 Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Control Run/Off/Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Operator Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Control Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Control Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Control Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Protection and Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Genset Protective Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Engine Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Alternator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Running Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Parade Rest Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Environmental Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
1302 Main Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

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SECTION TITLE PAGE
1302 Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Control Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Guidelines for Current Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Current Transformer Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Example of CT Sizing Two Lead CT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Example of CT Sizing Three Lead CT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Current Transformer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Two Lead CT Setup Example: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Three Lead CT Setup Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Battery Charging Alternator Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Denso Type Charging Alternators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Bosch Type Charging Alternators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Alternator Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Series Star . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Series Delta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Parallel Star . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Double Delta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Single Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Guidelines for Engine Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Coolant Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Oil Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Lube Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Control Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Electronic Governor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Setup, Trims, and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Alternator Control Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
AVR Enable/Disable Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Digital Output Voltage Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Torque-Matched Volts/Hz Overload Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Battleshort Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Genset Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
V/Hz Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Governor Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Engine Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Alternator Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Setup for Gain Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Gain Tuning Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Controller Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
1302 Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Remote Start Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Remote Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Local Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

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Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
12/24V Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Cycle Cranking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Spark Ignition Power/Glow Plug Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Glow Plug Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Preheat Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Glow Plug Output Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Start and Stop Time Delays (Cool Down) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Electronic Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Engine Speed Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Speed Governor Algorithm and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Real Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Excerise Scheduler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
ATS Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Dual Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Battle Short Mode Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Installations With an Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Installations Without an Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Battle Short Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Installations with an Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Installations without an Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

4. Operator Panel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1


Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Local Status Output Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Manual Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Emergency Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Installations with an Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Installations with a Manual Run/Off/Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Graphical Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Display Text / Symbolic Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Display Menu Selection Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Previous Main Menu Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Off Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Not In Auto Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Shutdown Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Warning Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Remote Start Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

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Auto Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Manual Run Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Operator Panel System Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Communication Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Event Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Fault Reset / Acknowledgement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Fault/Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Adjusting Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Saving Your Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Operator Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Engine Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Alternator Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Alternator Line-to-Line Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Alternator Line-to-Neutral Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Alternator Single Phase Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Alternator Amperage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Selecting Auto, Manual Run, and Off Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Entering the Mode Change Access Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Selecting Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Selecting Manual Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Aborting the Transition to Auto or Manual Run Mode . . . . . . . . . . . . . . . . . . . . . . 4-23
Selecting Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Network Status Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
History / About Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
History Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
About Genset Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
About Control Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
About Display Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Fault History Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Screen Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Adjusting Values/Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Screen Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

5. 1302 Control Panel Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1


Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Genset Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Viewing Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Viewing and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

iv
SECTION TITLE PAGE
Setup Password Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Adjusting Values/Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Genset Service Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Genset Menu, Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Genset Menu, Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Start/Stop Delay Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Cycle Crank Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Battle Short Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
AVR Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Electronic Governer Menu, Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Electronic Governer Menu, Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Genset Number Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Display Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Volts and Hertz Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Automatic Voltage Regular Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Volts/Hz Rolloff Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Regulator Gains Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Regulator Gains Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Electronic Governor Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Governor Crank Fuel Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Electronic Governor Regulator Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Electronic Governor Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Electronic Governor Enable Speed Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Customer I/O Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Fault Input Function Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Customer Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Fault Input Active State Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Customer Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Metering Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Meter Calib Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Freq. Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Metering Voltage Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Metering Current Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Annunciator Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Annunciator Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Annunciator Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
ModBus Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
ModBus Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
ModBus Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Genset Setup Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Viewing Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Viewing and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

v
SECTION TITLE PAGE
Genset Setup Password Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Adjusting Values/Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Genset Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Genset Menu 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Genset Menu 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Application Rating Select Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Standby kVA Rating Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Prime kVA Rating Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Battery Select Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Battery Threshold Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Battery Delay Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Oil Pressure Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Battery Select Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Battery Thresholds Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Battery Delay Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Oil Pressure Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Voltage Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
High AC Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Low AC Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Overfrequency Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Underfrequency Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Alternator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Current Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
High AC Current Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Engine Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Engine Protection Overspeed Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Engine Protection Speed/Frequency Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Low Oil Pressure Warning Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Low Oil Pressure Shutdown Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
High Coolant Temperature Warning Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
High Coolant Temperature Shutdown Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Engine Protection Low Coolant Temperature and Battery Charger Menus . . . . 5-53

6. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
PC Based Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Network Applications and Configurable Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Reading Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Reading Fault Codes Using Optional Operator Panel . . . . . . . . . . . . . . . . . . . . . . . 6-2
Reading Fault Codes Using the Control Switch Indicator . . . . . . . . . . . . . . . . . . . . 6-2
Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Voltage/Continuity Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

vi
7. Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Appendix A. 1302 Menu System Maps A-1

Appendix B. Index B-1


General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

vii
Foreword
The purpose of this manual is to provide the users with general control operation and fault code information.
Refer to the equipment manufacturers product support manuals for important safety precautions.

Manufacturers applying this control are respectfully advised that it is their responsibility to employ compe-
tent persons to carry out any installation work in the interests of good practice and safety. It is essential that
the utmost care is taken with the application of this control device.

Warranty
Warranty: This manual is published solely for information purposes and should not be considered all inclu-
sive. Sale of product shown or described in this literature is subject to terms and conditions outlined in ap-
propriate Cummins Power Generation selling policies or other contractual agreement between the parties.
This literature is not intended to and does not enlarge or add to any such contract. The sole source govern-
ing the rights and remedies of any purchaser of this equipment is the contract between the purchaser and
Cummins Power Generation.

NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PAR-


TICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEAL-
ING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS,
AND DESCRIPTIONS CONTAINED HEREIN.

In no event will Cummins Power Generation be responsible to the purchaser or user in contract, in tort (in-
cluding negligence), strict liability or otherwise for any special, indirect, incidental, or consequential damage
or loss whatsoever, including but not limited to damage or loss of use of equipment, plant or power system,
cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the
purchaser or user by its customers resulting from the use of the information, recommendations, and de-
scriptions contained herein.

viii
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS This manual contains EXHAUST GASES ARE DEADLY
important instructions that should be followed during
installation and maintenance of the generator and bat- Provide an adequate exhaust system to properly
teries. expel discharged gases away from enclosed or
sheltered areas and areas where individuals are
Before operating the generator set (genset), read the likely to congregate. Visually and audibly inspect
Operators Manual and become familiar with it and the the exhaust daily for leaks per the maintenance
equipment. Safe and efficient operation can be schedule. Make sure that exhaust manifolds are
achieved only if the equipment is properly operated secured and not warped. Do not use exhaust
and maintained. Many accidents are caused by failure gases to heat a compartment.
to follow fundamental rules and precautions.
Be sure the unit is well ventilated.
The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the oper-
Engine exhaust and some of its constituents are
ator, service personnel, or the equipment. known to the state of California to cause cancer,
birth defects, and other reproductive harm.
DANGER This symbol warns of immediate
MOVING PARTS CAN CAUSE SEVERE
hazards which will result in severe personal in-
jury or death. PERSONAL INJURY OR DEATH
Keep your hands, clothing, and jewelry away from
WARNING This symbol refers to a hazard or
moving parts.
unsafe practice which can result in severe per-
sonal injury or death. Before starting work on the generator set, discon-
nect battery charger from its AC source, then dis-
CAUTION This symbol refers to a hazard or connect starting batteries, negative () cable first.
unsafe practice which can result in personal in- This will prevent accidental starting.
jury or product or property damage. Make sure that fasteners on the generator set are
secure. Tighten supports and clamps, keep guards
FUEL AND FUMES ARE FLAMMABLE in position over fans, drive belts, etc.
Fire, explosion, and personal injury or death can result Do not wear loose clothing or jewelry in the vicinity
from improper practices. of moving parts, or while working on electrical
equipment. Loose clothing and jewelry can be-
DO NOT fill fuel tanks while engine is running, un- come caught in moving parts.
less tanks are outside the engine compartment.
Fuel contact with hot engine or exhaust is a poten- If adjustment must be made while the unit is run-
tial fire hazard. ning, use extreme caution around hot manifolds,
moving parts, etc.
DO NOT permit any flame, cigarette, pilot light,
spark, arcing equipment, or other ignition source DO NOT OPERATE IN FLAMMABLE AND
near the generator set or fuel tank.
EXPLOSIVE ENVIRONMENTS
Fuel lines must be adequately secured and free of
leaks. Fuel connection at the engine should be Flammable vapor can cause an engine to overspeed
made with an approved flexible line. Do not use and become difficult to stop, resulting in possible fire, ex-
zinc coated or copper fuel lines with diesel fuel. plosion, severe personal injury and death. Do not oper-
ate a genset where a flammable vapor environment can
Be sure all fuel supplies have a positive shutoff be created by fuel spill, leak, etc., unless the genset is
valve. equipped with an automatic safety device to block the air
Be sure battery area has been well-ventilated prior intake and stop the engine. The owners and operators of
to servicing near it. Lead-acid batteries emit a high- the genset are solely responsible for operating the gen-
ly explosive hydrogen gas that can be ignited by set safely. Contact your authorized Cummins Power
arcing, sparking, smoking, etc. Generation distributor for more information.

LS-14L

ix
ELECTRICAL SHOCK CAN CAUSE Keep multi-class ABC fire extinguishers handy.
SEVERE PERSONAL INJURY OR DEATH Class A fires involve ordinary combustible materi-
als such as wood and cloth; Class B fires, combus-
Remove electric power before removing protective tible and flammable liquid fuels and gaseous fuels;
shields or touching electrical equipment. Use rub- Class C fires, live electrical equipment. (ref. NFPA
ber insulative mats placed on dry wood platforms No. 10).
over floors that are metal or concrete when around
electrical equipment. Do not wear damp clothing Make sure that rags are not left on or near the gen-
(particularly wet shoes) or allow skin surface to be erator.
damp when handling electrical equipment. Do not
Make sure generator set is mounted in a manner to
wear jewelry. Jewelry can short out electrical con-
prevent combustible materials from accumulating
tacts and cause shock or burning.
under the unit.
Use extreme caution when working on electrical
components. High voltages can cause injury or Remove all unnecessary grease and oil from the
death. DO NOT tamper with interlocks. unit. Accumulated grease and oil can cause over-
heating and engine damage which present a po-
Follow all applicable state and local electrical tential fire hazard.
codes. Have all electrical installations performed
by a qualified licensed electrician. Tag and lock Keep the generator set and the surrounding area
open switches to avoid accidental closure. clean and free from obstructions. Remove any de-
bris from the set and keep the floor clean and dry.
DO NOT CONNECT GENERATOR SET DIRECT-
LY TO ANY BUILDING ELECTRICAL SYSTEM. Do not work on this equipment when mentally or
Hazardous voltages can flow from the generator physically fatigued, or after consuming any alcohol
set into the utility line. This creates a potential for or drug that makes the operation of equipment un-
electrocution or property damage. Connect only safe.
through an approved isolation switch or an ap-
proved paralleling device. Substances in exhaust gases have been identified
by some state or federal agencies as causing can-
GENERAL SAFETY PRECAUTIONS cer or reproductive toxicity. Take care not to breath
or ingest or come into contact with exhaust gases.
Coolants under pressure have a higher boiling
point than water. DO NOT open a radiator or heat Do not store any flammable liquids, such as fuel,
exchanger pressure cap while the engine is run- cleaners, oil, etc., near the generator set. A fire or
ning. Allow the generator set to cool and bleed the explosion could result.
system pressure first.
Wear hearing protection when going near an oper-
Used engine oils have been identified by some ating generator set.
state or federal agencies as causing cancer or re-
productive toxicity. When checking or changing To prevent serious burns, avoid contact with hot
engine oil, take care not to ingest, breathe the metal parts such as radiator, turbo charger and ex-
fumes, or contact used oil. haust system.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

LS-14L

x
1. Introduction
ABOUT THIS MANUAL CERTIFICATIONS
The 1302 series control meets or exceeds the re-
This manual provides installation and operation in- quirements of the following codes and standards.
formation regarding the 1302 series control. This
manual includes information for the following types NFPA110 for level 2 or 3 systems
of installations. ISO 85284: 1993 Compliance, Controls
and Switchgear
Kit 541141401 is for Hydro Mechanical
(HM) engines. CE Marking: The control system is suitable
for use on generator sets to be CEmarked
Kit 541141402 is for Full Authority Elec- EN 500811,2 Residential/Light Industrial
tronic (FAE) engines. FAE engines have an emissions or Industrial Emissions
external Electronic Control Module (ECM).
EN 500821,2 Residential/light industrial or
This manual does not have instructions for servic- Industrial susceptibility
ing printed circuit board assemblies. After deter- ISO 76372, level 2; DC supply surge volt-
mining that a printed circuit board assembly is age test
faulty, replace it. Do not repair it. Attempts to repair
a printed circuit board can lead to costly equipment Mil Std 202C, Method 101 and ASTM B117:
damage. Salt Fog test
This control is suitable for use on generator sets
This manual contains basic (generic) wiring dia- that are UL2200 listed.
grams and schematics that are included to help in
troubleshooting. Service personnel must use the Connector Seal Standards
actual wiring diagram and schematic shipped with The following standards apply to the connector
each unit. The wiring diagrams and schematics seals used with the 1302 series control.
that are maintained with the unit should be updated
when modifications are made to the unit. J11, J25, and J20 AMP 794758-1
J12 AMP 7942751 Interface seal and
Read Important Safety Precautions and careful- AMP 7942761 Wire seal (both are re-
ly observe all instructions and precautions in this quired)
manual.
J17 AMP 7942691 Interface seal and
SYSTEM OVERVIEW AMP 7942761 Wire seal (both are re-
quired)
The 1302 series control is a microprocessor-based
J18 AMP 7942711 Interface seal and
control. All generator set control functions are con-
AMP 7942761 Wire seal (both are re-
tained on one circuit board. The circuit board pro-
quired)
vides engine speed governing (optional, when the
governor output module and appropriate engine HOW TO OBTAIN SERVICE
equipment is provided), main alternator voltage
output regulation, and complete generator set con- Contact your generator set manufacturer when
trol protection and monitoring. seeking additional service information or replace-
ment parts. Provide model and serial number infor-
The operating software provides control of the gen- mation.
erator set and its performance characteristics, and
displays performance information on an optional WARNING Incorrect service or replacement of
operator panel. It accepts menu-driven control and parts can result in severe personal injury or
setup input from the push button switches on the death, and/or equipment damage. Service per-
operator panel. sonnel must be qualified to perform electrical
and mechanical service. Read and follow Im-
portant Safety Precautions, on pages v and vi.

1-1
THIS PAGE LEFT INTENTIONALLY BLANK

1-2
2. Description

FIGURE 2-1. 1302 MAIN CONTROL BOARD AND OPERATOR PANEL (HMI211)

OVERVIEW KIT DESCRIPTION


The PCC1302 controller is a microprocessor
based generator set (genset) monitoring, meter- The 1302 genset control kits include the 1302 con-
ing, and control system. The control provides a trol board (12/24V control assembly with run and
simple operator interface to the gensets digital start relay drivers) and the operator panel shown in
voltage regulation, engine speed governing, re-
Figure 2-1. Also included in these kits are the fol-
mote start / stop control, and protective functions.
lowing sensors and harnesses.
The PCC1302 control is suitable for use on hydro
mechanical or FAE engines. It can be used in non-
paralleling applications and it is compatible with re- Quantity
connectable alternators up to 600VAC. The control Description HM Kit FAE Kit
can also be configured for various frequency (50 / 541141401 541141402
60 Hz operation), voltage, and power connection
configurations from 190600 VAC L-L. Oil Pressure Sensor 1

The control is designed for mounting on the gener- Temperature Sensor 1


ator set. The 1302 series control is usually pow- Coolant Temperature
ered from the generator set starting batteries and 1
Sensor Harness
works over a voltage range from 8 to 30 VDC.
Oil Pressure Sensor
1
The 1302 series control meets NFPA 110 require- Harness
ments (with appropriate accessories) and is de-
Control Panel to
signed for connection to a 12 or 24 VDC control 1 1
PCC1302 Harness
system.
Engine Harness 1 1
An optional operator panel can be used as a user
interface. Genset AC Harness 1 1

2-1
ADDITIONAL EQUIPMENT HMI113 Universal Annunciator Kit
3005929 (Includes Operators Manual
Figure 2-1 shows the 1302 control module (327 9000301)
161701) and the optional HMI211 digital display
panel (3006014). If your installation is to include AUX101 System I/O Module Kit 5411291
any additional equipment (see Figure 2-2), the ap- (Includes Instruction Sheet C693)
propriate kit(s) must be purchased separately.
AUX104 External Governor Power Module
HMI112 LED Bargraph Kit 5411319 (In- Kit 5411231 (Includes Instruction Sheet
cludes Instruction Sheet C697) C689)

HMI112 LED BARGRAPH


(300605002)

AUX101 SYSTEM I/O MODULE


(3271536)

HMI113 UNIVERSAL ANNUNCIATOR AUX104 EXTERNAL GOVERNOR


(3005929) POWER MODULE (3271507)

FIGURE 2-2. ADDITIONAL EQUIPMENT

2-2
1302 CONTROL FEATURES Configurable Inputs and Outputs. Four dis-
crete configurable inputs and two dry contact
The 1302 series controller includes the following relay outputs.
features.
Relay driver output for glow plug or spark igniter
Operates on 12 or 24 VDC. controller, switched B+, FSO, Starter, Ready to
Load, Local Status, and Keyswitch control.
Electronic Governor Enable/Disable (via an
external Governor Power Module). Current Requirements
FAE Engine support utilizing partial PGI CAN The 1302 series control consumes 0.150 Amps of
protocol support. current while in idle mode. While in the running
mode, it consumes 0.75 Amps of current. This
Automatic Voltage Regulator (AVR) Enable/
doesnt include other application specific devices
Disable.
such as the optional operator panel, external
PMG or Shunt Excitation methods supported. actuators, relay coils, or display lamps.
PCCNet Communications. 1302 CONTROL SYSTEM
ModBus Communications. Control Module
Digital speed governing. The basic control system for the generator set
Digital voltage regulation. consists of a single control board with an external
control switch and status indicator.
Low power sleep mode, with configurable
Wake-In-Auto mode. The control board includes all the functions
necessary to locally or remotely start and stop the
Phase voltage and current sensing. Wye and Genset, provide digital voltage regulation, and
Delta voltage sensing single phase. Current protect the Genset.
sensing with an external 05 amp current
To use the electronic governor feature, an external
transformers.
governor power stage may be required to drive the
Engine relay drivers. fuel actuator.
Generator set monitoring. Display status of all Control Run/Off/Auto Switch
critical engine and alternator generator set
functions. Off Mode If the control is in the OFF mode, the
generator set is immediately shut down (if running)
Genset protection Engine and Alternator and cant be started. When in OFF mode, all active
protection features. faults are reset.
Operator Panel Display (optional). Provides Run Mode If the control is in the RUN mode, the
easy to use operator display of critical genset generator set will execute its start sequence and
parameters and operating history. operate at rated speed and voltage.
Advanced serviceability using a PC based Auto Mode If the control is in AUTO mode, the
software service tool. generator set can be started with a start signal from
a remote device, such as an automatic transfer
Environmental protection. The control system
is designed for reliable operation in harsh en- switch by accepting a ground signal.
vironments. The core control board is potted Fault Reset Placing the switch in the OFF posi-
module that is fully protected from the ele- tion also resets the active/inactive faults in the con-
ments. trol.

2-3
OPERATOR PANEL The Run/Off/Auto switch function is integrated into
the operator panel; therefore an external switch is
not required when a operator panel is installed. The
The 1302 series control is provided with an optional
operator panel displays current active faults, and a
operator panel that may be either locally or
time-ordered history of previous faults.
remotely mounted. The operator menus are made
up of English or internationally accepted symbols Operator Panel Connections
so translations are not required. The display is
Two connectors (J1 and J2) are located on the
composed of an adjustable contrast backlit LCD
back of the operator panel (see Figure 2-3).
display, with a series of 6 generator status LED
Connections are listed in Table 2-1.
lamps. The display is accompanied by a set of six
tactile feel membrane switches that are used by the NOTE: J1 and J2 are identical. Either one can be
operator to navigate through control menus, and to used for the harness connection between
make control adjustments. It is configurable for the main control board and the operator
units of measurement. panel.

1 5
2 6

3 7
4 8
PIN 1
J1 or J2

J2

J1
J1-4

FIGURE 2-3. 1302 OPERATOR PANEL

TABLE 2-1. OPERATOR PANEL CONNECTIONS


Connector Pin Signal Name Connect To / Comments
J1-1 RS-485 Data A Network Data A
J1-2 RS-485 Data B Network Data B
J1-3 B+ Network Supply
J1-4 PCCNet System Wake Up System Wakeup
J1-5 Return Network Supply Return
J1-6 Run Output
J1-7 Auto Output
J1-8

2-4
CONTROL INPUTS AND OUTPUTS Ready to load (generator set running) signal
This output pin goes low when the genset is
Control Inputs capable of supporting a load. The genset
Input signals to the main control board are: speed and voltage output are what determines
the state of this pin.
Run/Off/Auto switch
Communications connections The control
Remote start signal includes two RS-485 ports.
Remote emergency stop PC Tool Interface This communication
Local emergency stop port (TB15) allows the control to com-
municate with a personal computer run-
Coolant temperature signal ning a PC based service tool. This port
Lube oil pressure signal also allows the control to communicate
with external devices, such as a Pro-
Battery voltage signal
grammable Logic Controller (PLC) via
PCCNet System Wake Up Input the ModBus protocol.
Magnetic pick up signal PCCNet This communications port
Starter disconnect signal (TB1) allows for connection from the
control to the optional operator panel,
Single or three-phase current transformers universal annunciator, LED bargraph,
(CTs) and system I/O module.
Single or three phase line-to-neutral voltage Local status Refer to Local Status Output In-
Configurable inputs The control includes dicator on page 4-1.
four inputs that have configurable functions. Battery charging alternator Alternator flash
Once mapped, each configurable input can be connection
used as a fault input, remote fault reset input,
battleshort input, or disabled. Fuel shut-off relay driver

Control Outputs Starter relay driver


Keyswitch relay driver
Output signals from the control are:
Glow plug relay driver
Control status lamp.
Governor drive PWM command
Configurable relay outputs (OUT1_NO and
OUT2_NO) The control includes two relay Field coil AVR PWM command
outputs rated at two amps. These outputs can Excitation source Input power for field coil
be configured to activate on any control warn-
ing or shutdown fault as well as ready to load, Alternator line voltage sensing 600 VAC
not in auto, common alarm, common warning, RMS max
and common shutdown. Switched B+ driver

2-5
PROTECTION AND FAULTS PC based service tool or through the display
panel menus) to match the capabilities of the
The 1302 series control features genset protection engine used. The control includes time delays
functions and fault detection. to prevent nuisance warning/shutdown sig-
Upon operation of a protective function, the control nals.
will indicate a fault by flashing the fault code on the Low Coolant Temperature Warning This
local status lamp driver (J251). On systems with warning indicates that the engine temperature
an optional operator panel, the warning or may not be high enough for a 10-second start
shutdown LED lights and the fault symbol and code or proper load pickup. The level is preset (con-
is displayed on the display. The nature of the fault figurable with a PC based service tool or
and time of occurrence is logged in the control. The through the display panel menus) to match the
service manual and PC based service tool provide capabilities of the engine used. The control in-
service keys and procedures based upon the cludes time delays to prevent nuisance warn-
service codes provided. ing signals.
Low Battery Voltage Warning This warning
Fault Codes indicates a battery charging system failure by
continuously monitoring battery voltage. The
A list of fault/status codes is included in Section 4. control includes time delays to prevent nui-
Shutdown faults will shutdown the genset. Warning sance warning signals.
faults are issued to notify the genset operator of the
High Battery Voltage Warning This warn-
problem but the 1302 series control will not shut-
ing indicates that the battery charging system
down the genset when they occur.
is of a high level by continuously monitoring
Genset Protective Functions battery voltage. The control includes time de-
lays to prevent nuisance warning signals.
The control provides the following system protec-
tive functions: Weak Battery Voltage Warning The control
system tests the battery bank each time the
Configurable Alarm and Status Inputs The generator set is signaled to start. A warning is
1302 series control accepts up to four alarm or announced if the generator set battery indi-
status inputs (configurable contact closed to cates impending failure. The control includes
ground or open) to indicate customer-speci- time delays to prevent nuisance warning sig-
fied conditions. The control is programmable nals.
for warning, shutdown, or status indication,
and for labeling the input. Dead Battery Voltage Shutdown Indicates
battery voltage drop during cranking which re-
Emergency Stop Annunciated whenever the sets control for three consecutive times (This
emergency stop signal is received from an ex- feature is available in 1302 calibration version
ternal switch. 3.0 onwards )
Engine Protection Fail to Start (Overcrank) Shutdown.
Overspeed Shutdown The engine over- Fail to Crank Shutdown This shutdown in-
speed default setting is 115% of the rated en- dicates that the control signaled the starter to
gine speed nominal. The control includes time crank the engine but the engine did not rotate.
delays to prevent nuisance shutdown signals. Cranking Lockout The control will not allow
Low Lube Oil Pressure Warning/Shutdown the starter to attempt to engage or to crank the
The level is preset (configurable with a PC engine when the engine is rotating (when the
based service tool or through the display panel control senses the valid engine RPM above
menus) to match the capabilities of the engine the noise threshold value.)
used. The control includes time delays to pre-
Sensor Failure Indication An out-of-range
vent nuisance warning/shutdown signals.
high or low diagnostic logic is provided on the
High Engine Temperature Warning/Shut- base control to detect analog sensor or inter-
down The level is preset (configurable with connecting wiring failures.

2-6
Alternator Protection Under/Overfrequency The underfrequen-
cy default is 6Hz of the 50 Hz / 60 Hz frequen-
High/Low AC Voltage Shutdown The high cy with a 10 second time delay. The overfre-
voltage default setting is 110% of the rated quency default is + 6Hz of the 50 Hz / 60 Hz fre-
voltage with a 10 second time delay. The quency with a 10 second time delay.
instantaneous voltage default setting is 130%
of the rated voltage. The low AC voltage de- Loss Of Sensing AC Voltage Shutdown
fault setting is 85% of the rated voltage with a Loss of sensing AC voltage detects the loss of
10 second time delay. voltage sensing or senses the loss of zero
Overcurrent Warning/Shutdown Imple- crosses. This fault will also be the primary way
mentation of the thermal damage curve with to detect short circuit conditions.
an instantaneous trip level is calculated based
Overexcitation Shutdown Overexcitation
on the Current Transformer Ratio and the Ap-
is used to detect short circuit alternator faults.
plication Power Rating (see Figure 2-4).

CURRENT DRAW
Alternator
Thermal The current draw information below is for the 1302
Damage Curve series control only. It does not include current draw
for other application specific devices, such as the
Overcurrent optional operator panel, external actuators, relay
Protection coils, or display lamps.
Curve
Running Mode
10 When in Running mode, the 1302 series control
consumes .750 amps of current.
Seconds
1 Parade Rest Mode

Instantaneous Parade Rest mode is when the 1302 series control


Trip Point is waiting for a start command (for example, the
genset is not running). During Parade Rest mode,
the control consumes 150 milliamps of current.
0.03
Sleep Mode

1 10 Amps (x rated) The 1302 series control enters Sleep mode after
five minutes in the Off or Auto mode. During Sleep
FIGURE 2-4. ALTERNATOR PROTECTION mode, the control consumes 60 milliamps of cur-
THERMAL DAMAGE CURVE rent.

2-7
THIS PAGE INTENTIONALLY LEFT BLANK

2-8
3. Installation
Read these instructions completely and become charger before disconnecting battery cables.
familiar with safety warnings, cautions, and proce- Arcing can ignite explosive hydrogen gas giv-
dures before starting the installation. en off by batteries, causing severe personal in-
jury. Arcing can occur when a cable is removed
WARNING Incorrect installation, service, or or re-attached, or when the negative () battery
replacement of parts can result in severe per- cable is connected and a tool used to connect
sonal injury or death and/or equipment dam- or disconnect the positive (+) battery cable
age. Only trained and experienced personnel touches the frame or other grounded metal part
are to perform the following procedures. of the generator set. Always remove the nega-
tive () cable first, and reconnect it last. Make
CAUTION A generator set control must be
certain hydrogen from the battery, engine fuel,
serviced only by technically qualified person-
and other explosive fumes are fully dissipated.
nel. High voltages are present. These voltages
This is especially important if the battery has
can cause electrical shock, resulting in person-
been connected to a battery charger.
al injury.
Even with power removed, improper handling WARNING Ignition of explosive battery gases
of components can cause electrostatic dis- can cause severe personal injury or death. Arc-
charge and damage to circuit components. ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can
WARNING AC voltages and currents present ignite battery gas. Do not smoke, or switch
an electrical shock hazard that can cause se- trouble light ON or OFF near a battery. Dis-
vere personal injury or death. Incorrect instal- charge static electricity from body before
lation, service, or parts replacement can result touching batteries by first touching a grounded
in severe personal injury, death, and/or equip- metal surface.
ment damage.
MOUNTING GUIDELINES
Turn off or remove AC power from the battery char-
ger (if present) and then remove the negative () The main control board and the optional operator
battery cable from the set starting battery. This is to panel are suitable for non-engine mounting. As
make sure the genset will not start while working on such, they should not be directly mounted on the
it and to avoid circuit board damage, caused by engine.
voltage spikes when removing and replacing circuit
board connectors. The control and operator panel may be mounted on
one of the following.
CAUTION If present, always disconnect a bat-
tery charger from its AC source before discon- A suitable frame on top of the alternator
necting the battery cables. Otherwise, discon- A frame supported from the genset base rail
necting the cables can result in voltage spikes A stand-alone mounting frame isolated from
high enough to damage the DC control circuits the vibration of the genset
of the generator set.
Appropriate vibration isolators should be used to
WARNING Accidental starting of the genera- make sure that neither the main control board, the
tor set while working on it can cause severe operator panel, nor customer wiring are subjected
personal injury or death. Prevent accidental to vibration levels beyond their capability.
starting by disconnecting the starting battery
cables (negative [] first). To prevent the control board and the optional oper-
ator panel from being exposed to conditions be-
Make certain the battery area has been well- yond their specifications, care should be taken not
ventilated before servicing the batteryWear to mount them close to the engine exhaust pipes.
gogglesStop the genset and disconnect the Mounting them in a manner that would expose

3-1
them to direct sunlight or rain/snow should also be LCD Vibration Profile
avoided. Amplitude (Gs)
10
It is recommended that the control board be
mounted with the longer side horizontal and the
shorter side vertical so as to allow air to move freely
upwards through the heat sink channels. Mounting
the control board with the short side horizontal and 1
the longer side vertical should be avoided.

ENVIRONMENTAL CAPABILITY
0.1
The control system is specifically designed and 0 50 100 150 200 250
tested for resistance to RFI / EMI and to resist the
effects of vibration to provide a long reliable life Frequency (Hz)
when mounted on a generator set. The control in-
cludes transient voltage surge suppression to pro- FIGURE 3-1. OPERATOR PANEL VIBRATION
vide compliance to referenced standards. LIMITS
1302 Main Control Board CONTROL WIRING INFORMATION
The main control board is designed to withstand For connecting the Magnetic Pickup, use mini-
vibration levels of 50 mm / sec in the 20100 Hz mum 0.8 sq. mm (18 gage), 2 conductors,
range and of 3.3 G in the 1002000 Hz range. twisted shielded cable. Connect the shield at
J11-8 and leave the shield un-connected at the
The main control board is designed for proper op-
magnetic pickup side of the cable.
eration without recalibration in ambient tempera-
tures from 40 to +70 Deg C, and for storage from For connection the ECM CAN, use minimum
55 to +80 Deg C. The control is designed to oper- 0.8 sq. mm (18 gage), 2 conductors, twisted
ate with humidity up to 95%, non-condensing, and shielded cable. Connect the shield at
at an altitude up to 13,000 feet (5000 meters). J11-17and leave the shield un-connected at
the ECM side of the cable.
The main control board is fully encapsulated to pro- For connecting the PCCNet, use minimum 0.8
vide resistance to the effects of dust and moisture. sq. mm (18 gage), 2 conductors, twisted
cable.
1302 Operator Panel
For connecting the battery supply, use two
The optional operator panel is designed to with- twisted pair wires (16 AWG).
stand vibration levels of 40 mm / sec in the 4100 For connecting current transformers, use
Hz range and the engine vibration levels shown in three twisted pair wires minimum (16 AWG).
Figure 3-1.
For all other connections, use minimum 0.8 sq
The operator panel is designed for proper opera- mm (18 gauge) wires.
tion in ambient temperatures from 4 to 158 Deg F The Electronic Governor feature typically re-
(20 to +70 Deg C) and for storage, from 22 to 176 quires an external Governor Output Module
Deg F (30 to +80 Deg C). Kit. Governor PWM output from the 1302 se-
ries control board is connected as input to the
The operator panel has a single membrane sur- Governor Power Module by a minimum 0.8 sq.
face, which is impervious to the effects of dust, mm (18 gage), 2 conductors, twisted shielded
moisture, oil, and exhaust fumes. cable.

3-2
GUIDELINES FOR CURRENT Current Transformer Selection
TRANSFORMERS Current transformers (CTs) used in 1302 control
All current transformers (CTs) used with a 1302 se- applications are ideally sized to produce rated CT
ries control must conform to the following specifica- secondary amps at twice rated generator (full
tions. 200% range) output amperes. In other words,
when the generator is producing 100% output am-
Continuous rated full load secondary output
peres, the secondary current of the CTs is 2.5 am-
current: 5 amps at 50 or 60Hz
peres per phase. This requirement determines a
Total burden VA rating: at least 2.5 VA lower bound of the CT ratio. An upper bound is de-
Output terminals between which current is termined by requiring that, at 100% rated output
drawn in high and low ranges on tapped CTs. current, the CTs secondary current is at least 1 am-
Maximum allowable ratio error at rated output: pere. The purpose of this is to maintain sufficient
+/1% metering resolution. The lower and upper bound of
the CT limits are prescribed by the following two
Maximum allowable phase error at rated out-
formulas.
put: +/1
2 * Max_Rated_Current
10-second overload output current in rated Minimum CT Ratio =
metering load: 10 Amps 5

Maximum allowable ratio error at overload 5 * Min_Rated_Current


output: +/1% Maximum CT Ratio =
5
Ambient temperature rating: 40 to 176 Deg F
(40 to +80 Deg C) In non-reconnectable genset applications, the
System voltage rating 600VAC Max_Rated_Current and Min_Rated_Current are
the same. In reconnectable genset applications,
NOTE: in PCC1302,if trim parameter they are different.
Current Multiplier 2X Enable is
enabled and only one of the two Example of CT Sizing Two Lead CT
alternator winding phase cables A 250kVA rated genset application at 240V pro-
is routed through CT, then the cur-
duces rated output current of 602 amps/phase.
rent measurement calculation will
This yields a Minimum CT Ratio of 1204:5 and a
be multiplied by 2 to show the cor-
Maximum CT Ratio of 3010:5. Any CT with a ratio
rect reading of the load current.
between these two values would be sufficient for
this application.

3-3
Example of CT Sizing Three Lead CT 1. Enter an appropriate value in the CT ratio pa-
rameter on the operator panel.
A reconnectable generator capable of 208240/
416480V outputs with a 125 kVA 3-phase only rat- 2. Select a feature to be downloaded using the
ing. Manufacturing Tool.
You first need to find the current in each phase for 3. Program an appropriate value in the Primary
each output voltage. This is done using the follow- CT Current parameter using a PC-based ser-
ing formula: vice tool (for example, InPower).
Power (VA )
Current
3 *Voltage NOTE: To check the actual genset output, True
(calibrated) RMS meter should be
or
usedThe 1302 series control automatically
Power (W ) doubles the entered CT ratio when switch-
Current
3 * Power_ Factor *Voltage ing from high nominal voltage (above
Using the above equation, the current in each 300V) to lower nominal voltage (below
phase is computed as shown below. 300V).
When entering a CT ratio the following rules apply:
Voltage (V) Output Current (A)
208 346.376 Two Lead CT, above 300V application Enter
240 300.192 CT ratio as read from the CT.
416 173.188 Two Lead CT, below 300V applications Enter
480 150.096 HALF of the CT Ratio as read from the CT.
Three Lead CT (Center Tapped) Enter the
The next step is to use the equations on page 3-3 SMALLER of the two ratios as read from the
to find the lower and upper bound for the CT ratios CT.
for each voltage configuration.
Two Lead CT Setup Example:
For a 208240 voltage configuration: For this example, assume a CT with a 1500:5 ratio
Maximum CT Ratio 5 * 300.192 1500.96 is being used.
Operator Panel
Minimum CT Ratio 2 * 346.376 692.752
Above 300V applications Enter 1500 into the
For a 416480 voltage configuration: CT ratio parameter on the operator panel.
Maximum CT Ratio 5 * 150.096 754.8 Below 300 V applications Enter 750 into the
Minimum CT Ratio 2 * 173.188 346.376
CR ratio parameter on the operator panel.
Manufacturing Tool
For three-tap CTs, it would be advisable to choose
a CT with a 1500/750:5 ratio. Above 300V applications Select a feature
corresponding to 1500:5 to download using
For the 208240 voltage configuration, connect
the Manufacturing Tool.
the CT leads to the 1st and 3rd CT connections,
leaving the center tap disconnected. Below 300 V applications Select a feature
For the 416480 voltage configuration, use the corresponding to 750:5 to download using the
same 1500/750:5 ratio CT, but this time connect Manufacturing Tool.
the CT leads to the first and second (center-tap) PC-Based Service Tool
connections on the CT, leaving the third tap uncon-
Above 300V applications Enter 1500 into the
nected.
Primary CT Current parameter, using the PC-
Current Transformer Setup based service tool (e.g. InPower).
After the 1302 series control kit has been installed, Below 300V applications Enter 750 into the
the controller must be programmed to use the CT Primary CT Current parameter, using the PC-
by one of the following methods. based service tool (e.g. InPower).

3-4
In PCC1302 Control, Voltage Calibration point ( i.e. for example: If the user wants the
procedure is divided into three processes PCC to output 215VAC instead of 220VAC)
as described below:
Procedure of calibrating the Alternator
1. Meter Calibration: There are two sets of AC in- Voltages is as follows:
puts on the 1302: L1N, L2N, and L3N (or
L12, L23, L31 for delta) AND 3 phase aver- Safety Precautions:
age voltage. The metering calibration will cali- 1. Contacting high voltage components can
brate L1N, L2N, L3N., which is used for cause electrocution, resulting in severe per-
display and diagnostic purposes. Method: sonal injury or death. Calibration and adjust-
Verify each phase on PCC matches external ment must be performed by technically quali-
calibrated meter. This calibration should be fied personnel only. Read and observe all the
done first. Warnings and Cautions in your generator set
2. Regulation Calibration: This calibrates the 3 manuals.
phase average voltage, which is used for reg-
2. Improper calibration and adjustment of the
ulation. Method: Verify the 3 phase average
PCC can cause equipment malfunction or
voltage of the genset matches an external me-
damage. Calibration and adjustment must be
ters voltage. Special note: When changing
performed by technically qualified personnel
the regulation feedback calibration, the PCCs
only.
feedback will appear to say the same, and the
external meters value will change. This is be- One or more of the PCCs internal circuits may
cause the PCC regulator is active, and is mak- need to be calibrated, in which case you should cal-
ing what the PCC sees be the PCCs Setpoint. ibrate the internal circuits in the following order
listed in the table shown below:
3. Voltage Adjust: Once both the metering and
voltage calibration is done, you use the volt- NOTE: To check the actual genset output, True
age adjust to modify the PCCs voltage Set- (calibrated) RMS meter should be used.

3-5
TABLE 3-1. CALIBRATION
Component
p to be calibrated Calibration method
PC based service tool Operating panel
Meter Calibration or Voltage mea- 1. Connect to the control with your 1. View the service menu by holding
surement for display PC based service tool. down the up and down arrow keys
2. Verify the nominal voltage trim is on any of the operating menus.
set to the desired value. The trim Al- 2. Select item 1, Setup Menu.
ternator Nominal Voltage is available 3. Enter Setup menu password
at Adjustments > AC Measurement 574.
Calibrations > Voltage Measure-
ment for Regulation. Set the Alterna- 4. Select item 1, Genset Service.
tor Nominal Voltage to the voltage 5. Select item 1, and verify the Volts
that the genset will generate. AC setting is correct for your ap-
3. With the genset OFF, attach a cali- plication. If necessary press the Ad-
brated Voltmeter to the AC Output just button and change the setting,
from L1 to L2. (L1 to Neutral for and press the Save button.
single phase alternators). 6. Press the back button to return to
4. Start the genset and allow it to service menu.
reach normal operating speed. 7. With the genset OFF, attach a cali-
5. Calibrate voltage reading for L1 by brated Voltmeter to the AC Output
adjusting the trim Alternator L1N from L1 to L2. (L1 to Neutral for
50Hz Voltage Display Adjust or Alter- single phase alternators).
nator L1N 60Hz Voltage Display 8. Start the genset and allow it to
Adjust trim for your application, so reach normal operating speed.
that the reading on the display 9. Select item 3, Meter Calib.
agrees with the calibrated voltmeter.
10. Press the down arrow twice to
6. Shut the generator set OFF. scroll down to the Metering Voltage
7. Repeat Step 3 to Step 6 for L2 Adjust
and L3 (In Step 3 attach meter to the 11. Adjust the three parameters one
AC output from L2 to L3 to calibrate by one listed so that the reading on
L2 and L3 to L1 to calibrate L3) by the display agrees with the calibrated
adjusting the trims Alternator L2N voltmeter.
50Hz Voltage Display Adjust or Alter-
nator L2N 60Hz Voltage Display 12. Shut the generator set OFF.
Adjust trim and Alternator L3N 13. Repeat Step 7 to Step 12 for L2
50Hz Voltage Display Adjust or Alter- and L3 (In Step 3 attach meter to the
nator L3N 60Hz Voltage Display AC output from L2 to L3 to calibrate
Adjust trim respectively. L2 and L3 to L1 to calibrate L3) by
8. Save the adjustments by doing a adjusting the trims Alternator L2N
Save Trims with your PC based ser- 50Hz Voltage Display Adjust or Alter-
vice tool. nator L2N 60Hz Voltage Display
Adjust trim and Alternator L3N
50Hz Voltage Display Adjust or Alter-
nator L3N 60Hz Voltage Display
Adjust trim respectively.
14. Save the adjustment by pressing
the Save button.

3-6
Regulation Calibration or Voltage 1. Connect to the control with your 1. View the service menu by holding
measurement for regulation PC based service tool. down the up and down arrow keys
2. Verify the nominal voltage trim is on any of the operating menus.
set to the desired value. 2. Select item 1, Setup Menu.
3. With the genset OFF, attach a cali- 3. Enter Setup menu password
brated Voltmeter to the AC Output 574.
from L1 to L2. 4. Select item 1, Genset Service.
4. Start the genset and allow it to 5. Select item 1, and verify the Volts
reach normal operating speed. AC setting is correct for your ap-
5. Adjust the trim Voltage Regulation plication. If necessary press the Ad-
Calibration 50Hz or Voltage Regula- just button and change the setting,
tion Calibration 60Hz for your desired and press the Save button.
application. The effect of this trim is 6. Press the back button to return to
Inverse on the regulated voltage. In- service menu.
creasing the trim will lower the regu-
lated voltage, and decreasing the 7. Start the genset and allow it to
trim will raise the regulated voltage. reach normal operating speed.
The monitored Regulated Voltage 8. Select item 3, Meter Calib.
will match with the reading on the at- 9. Press the Adjust button and
tached external calibrated meter and change the Reg Volt Adj value. The
the Regulated Feedback Voltage (Al- effect of this trim is Inverse on the
ternator Voltage) matches the de- regulated voltage. Increasing the trim
sired Nominal voltage. will decrease the regulated voltage.
6. Shut the generator set OFF. Decreasing the trim will increase the
7. Save the adjustments by doing a regulated voltage.
Save Trims with your PC based ser- 10. Save the adjustment by pressing
vice tool. the Save button.
Voltage Setpoint Adjustment 1. Connect to the control with your Not Applicable.
PC based service tool.
2. Verify the nominal voltage trim is
set to the desired value.
3. With the genset OFF, attach a cali-
brated Voltmeter to the AC Output
from L1 to L2.
4. Start the genset and allow it to
reach normal operating speed.
5. Adjust the trim Voltage Adjust
which shall move the voltage Set-
point either in positive direction or in
negative direction as per your re-
quirement.
NOTE:
1. Meter Calibration is what all the diagnostics use and the display shows, while Regulator Calibration it the
feedback going to the AVR. Thus Meter Calibration and the Regulator calibration shall be done when the
PCC1302 control is initially calibrated or if the boards are swapped / replaced with the new ones.
2.Voltage Setpoint adjustment shall be carried out as and when required to move the voltage Setpoint.

3-7
Three Lead CT Setup Example BATTERY CHARGING ALTERNATOR
CONNECTIONS
For this example, assume that a CT with a
1500/750:5 ratio is being used. The 1302 series control currently supports the fol-
lowing charging alternator types.
Operator Panel
Denso Type Charging Alternators
Enter 750 into the CT Ratio parameter on the
Operator Panel. A Denso charging alternator with IG and L (failure
lamp) connection points is shown in Figure 3-2.
Manufacturing Tool This configuration is used to produce a start dis-
connect signal and to indicate a failed battery
Select a feature corresponding to 750:5 to charging alternator.
download using the Manufacturing Tool.
Bosch Type Charging Alternators
PC-Based Service Tool
A Bosch charging alternator with D+ (flash input)
Enter 750 into the Primary CT Current param- connection point is shown in Figure 3-3. This con-
eter using a PC based service tool (e.g. In- figuration is used to produce a start disconnect sig-
Power). nal and to indicate a failed charging alternator.

Denso Type 1302 Series Control


Charging Alternator Battery Charging
J2022 Alternator Input
L

RUN
J2011
IG B+

FIGURE 3-2. DENSO CHARGING ALTERNATOR WIRING DIAGRAM

1302 Series Control


Bosch Type
Charging Alternator Battery Charging
D+ J2022 Alternator Input

Approx, 5 Ohm
input impedance
RUN
J2011
B+

FIGURE 3-3. BOSCH CHARGING ALTERNATOR WIRING DIAGRAM

3-8
ALTERNATOR CONNECTIONS J12-1 J12-4
A fast acting UL certified ceramic fuse with a rating W6 (T12)
V1: J22-1

of ten amperes shall be placed inline with the Ex- U1 (T1) CT1
citation Inputs J18-1 and J18-2.
Series Star W5 (T9) VN: J22-4
W2 (T6)
Series star connection yields an output voltage of
220277/380480 volts. Figure 3-4 shows the cor- J12-3 J12-6
rect seriesstar alternator connections. W1 (T3)
V3: J22-3
U2 (T4) V6 (T11)
CT3
U5 (T7)
J12-1 J12-4 J12-2 J12-5
V1: J22-1 V2: J22-2 V5 (T8)
V2 (T5)
U1 (T1) CT1 CT2
V2 (T5)

V1 (T2)
U2 (T4)
V6 (T11) J12-2 J12-5
U5 (T7) V1 (T2)
U6 (T10) V2: J22-2
CT2
V5 (T8)
U6 (T10) VN: J22-4
W6 (T12)
FIGURE 3-5. SERIES DELTA CONNECTIONS

W5 (T9)

W2 (T6)

J12-3 J12-6
W1 (T3)
V3: J22-3
J12-1 J12-4
CT3
V1: J22-1 J12-2 J12-5
CT1 V6 (T11)
FIGURE 3-4. SERIES STAR CONNECTIONS U5 (T7)
V2: J22-2
CT2
V2 (T5)
Series Delta U6 (T10)
V5 (T8)
Series delta provides for an output voltage of U1 (T1)
110120/220240 volts. Figure 3-5 shows the cor- V1 (T2)
U2 (T4)
rect series delta connections. VN: J22-4

NOTE: To check the actual genset output, True W6 (T12) W2 (T6)


(calibrated) RMS meter should be
usedSense N must not be connected in
three phase delta connections.
J12-3 J12-6
W5 (T9) W1 (T3)
Parallel Star V3: J22-3
CT3
Parallel star alternator configuration yields an out-
put voltage of 110139/190240 volts. Figure 3-6
illustrates the correct parallel star connections. FIGURE 3-6. PARALLEL STAR CONNECTIONS

3-9
Double Delta Single Phase
The double delta alternator configuration yields an Single phase provides for an output voltage of
output voltage of 110120/220240 volts. Correct 110120/220240 volts. Single phase alternator
double delta connections are illustrate in Figure connections are shown in Figure 3-8.
3-7.

J12-1 J12-4
J12-1 J12-4
V1: J22-1 V1: J22-1
V6 (T11) U1 (T1)
CT1 U5 (T7)
CT1

V5 (T8)

W2 (T6)

U2 (T4) U6 (T10)
W1 (T3)
VN: J22-4 VN: J22-4
V2 (T5) U1 (T1)
U5 (T7)

V1 (T2)

W6 (T12)
J12-2 J12-5
J12-2 J12-5 U2 (T4)
U6 (T10) V2: J22-2
W5 (T9) V2: J22-2
CT2
CT2

FIGURE 3-7. DOUBLE DELTA CONNECTIONS FIGURE 3-8. SINGLE PHASE CONNECTIONS

3-10
GUIDELINES FOR ENGINE SENSORS For information on setting the oil pressure sender
type using the display panel, see page 5-43.
The engine sensors included in this kit are:
Coolant Temperature Sensor 193052901
Oil Pressure Sensor 1930444
This section provides information on these plus
additional engine sensors that can be used with
1302 series controllers.
Coolant Temperature Sensors
The coolant temperature sensors that are avail-
able from Cummins Power Generation (CPG) are
listed in Table 3-1.
FIGURE 3-9. THREE-WIRE PRESSURE SENSOR
The coolant temperature sensor connectors that CONNECTIONS
are available from CPG are listed in Table 3-2.
Oil Pressure Sensors
The 1302 series control can be programmed for ei-
ther oil pressure sensors or switches. The trim pa-
rameter for this is: Lube Oil Pressure Sensor Type
= Sensor, Switch. If the type is set to Sensor, the
control can also be programmed for either 3-wire or
2-wire sensors. The trim parameter for this is Oil
Pressure Sender Type = 3-wire, 2-wire. Available FIGURE 3-10. TWO-WIRE PRESSURE SENSOR
switch and sensors are listed in Table 3-3. CONNECTIONS

TABLE 3-1. COOLANT TEMPERATURE SENSORS


CPG P/N Manufacturer / P/N Resistive Temp Range Threading
0193052901 AirPax / 50240250 40 to +230 F 3/8 NPTF
0193052902 AirPax / 50240274 40 to +230 F M14 X 1.5 with O Ring

TABLE 3-2. TEMPERATURE SENSOR CONNECTORS


CPG P/N Manufacturer Manufacturer P/N Comments
03231755 Packard 121621893 Plastic shell with seal
03231818 Delphi 12124075 Socket Connector

3-11
TABLE 3-3. OIL PRESSURE SENSORS AND SWITCH
Manufacturer / Range / Resistance /
CPG P/N Sensor Type Comments
P/N Unit Voltage
193043002 F.W. Murphy 2-Wire Standard 0100 PSIG 24033 Includes 10-32 hex nut
ED2P-100 Resistive Sender Ohms connectors, 1/8 NPTF dry
sealing threading, and a
diaphragm operated resis-
tive sensing element
1930444 Kavlico 3-Wire Active 0100 PSIG 05 VDC Mating Connector
P1655110 Sender 3261666 (Packard
(Capacitive) 12065287) includes
3231667 socket termi-
nals (Packard 12103881)
3090641XX Stewart Warner Pressure Switch (See the following page)
A028X493 Kavlico 3-Wire Active 0100 PSIG 05 VDC Mating Connector
P405550011 Sender 3261666 (Packard
(Capacitive) 12065287) includes
3231667 socket termi-
nals (Packard 12103881)

Lube Oil Pressure Switch For information on setting the oil pressure switch
polarity using the display panel, see page 5-43.
The part number for the Lube Oil Pressure Switch
is 3090641XX. The XX portion of the number is
dependent the trip pressure point. Refer to Table
3-4 to select an appropriate lube oil pressure
switch.
If an oil pressure switch is used, the active state
(active high or active low) of the switch must be
configured using a PC based service tool or
through the menus available with the operator pan-
el. A software setting allows for selection of the ac-
tive state of the switch. The Lube Oil Pressure
Switch Polarity can be set to Active High or Active
Low. FIGURE 3-11. PRESSURE SWITCH

TABLE 3-4. AVAILABLE PRESSURE SWITCHES (3090641)

Part No. Set Point Contact (At Rest) No. of Terminals


309064101 14 2.0 PSI Closed 1
309064102 14 2.0 PSI Open 2
309064103 14 2.0 PSI Closed 2
309064104 9 1.5 PSI Open 2
309064105 9 1.5 PSI Closed 1
309064106 10 1.5 PSI Open 2
309064107 20 2.0 PSI Closed 1
309064108 20 2.0 PSI Closed 2
309064110 20 3.0 PSI Closed 2

3-12
309064113 30 3.0 PSI Closed 1
309064114 4 1.0 PSI Open 2
309064115 5 1.0 PSI Open/Closed 3
309064116 5 1.0 PSI Closed 1
309064117 5 1.0 PSI Open 1
309064118 5 1.0 PSI Open 2
309064119 14 2.0 PSI Closed 2
309064120 20 2.0 PSI Closed 1
All pressure switches have steel base and nipple construction.

3-13
CONTROL BOARD CONNECTIONS J12 Genset CT connections (see Table 3-8)
The 1302 control board includes the following J17 Field winding connections (see Table
connectors (see Figure 3-12). 3-9)
CAUTION Reversing the power supply con- J18 Field power connections (see Table
nections on TB1 and/or TB15 can permanently 3-10)
damage the control. Refer to drawing 6303270
for proper connections. J20 Genset connections (see Table 3-11)

TB1 Customer connections (see Table 3-5 J22 Alternator voltage sense connections
and sheet 3 of Figure 7-1) (see Table 3-12)
TB15 Tools interface connections (see Table J25 Display connections (see Table 3-13)
3-6 and sheet 3 of Figure 7-1) Mating connector and connector pin part numbers
J11 Engine connections (see Table 3-7) for the control board are listed in Table 3-14.

J12 (CT TB15 (PC BASED


J22 (ALTERNATOR
CONNECTIONS) SERVICE TOOL)
VOLTAGE SENSE)

J17 (FIELD
POWER)

J18 (FIELD J11 (ENGINE


POWER) CONNECTIONS)

J20 (GENSET
CONNECTIONS)

TB1 (CUSTOMER J25 (DISPLAY


CONNECTIONS) CONNECTIONS)

FIGURE 3-12. CONTROL BOARD CONNECTIONS

3-14
TABLE 3-5. TB1 CUSTOMER CONNECTIONS
Pin Signal Name Connect To
TB1-1 PCCNet A Network Data A
TB1-2 PCCNet B Network Data B
TB1-3 PCCNet Shield / B+ Return
TB1-4 Ready to Load 20ma Low Side Relay Driver
TB1-5 B+ Output (5A)
TB1-6 Configurable Relay 1 A
TB1-7 Configurable Relay 1 B
TB1-8 Configurable Relay 2 A
TB1-9 Configurable Relay 2 B
TB1-10 Remote Start Return
TB1-11 Remote Start
TB1-12 Configurable Input 1 Pull to TB1-13 to activate input. Remove from TB1-13 to
deactivate input.
TB1-13 Configurable Input Common Common for the two fault inputs
TB1-14 Configurable Input 2 Pull to TB1-13 to activate input. Remove from TB1-13 to
deactivate input.
TB1-15 Remote E-STOP Return Remote normally closed E-STOP switch
TB1-16 Remote E-STOP Remote normally closed E-STOP switch

TABLE 3-6. TB15 TOOLS INTERFACE CONNECTIONS


Connector Signal Name Connect To
Pin
TB15-1 Return Network Power Supply Return
TB15-2
TB15-3 RS-485 Data A Network Data A
TB15-4 RS-495 Data B Network Data B
TB15-5 PCCNet System Wakeup

3-15
TABLE 3-7. J11 ENGINE CONNECTIONS

Connector Pin Signal Name Connect To


J11-1 Oil Pressure Sender (Active) +5V
J11-2 Oil Pressure Sender or Switch Re-
turn
J11-3 Oil Pressure Sender
J11-4 Governor Drive Governor PWM low side driver
J11-5 Governor Drive + Governor drive + (for low side driver)
J11-6 Relay Coil B+ Coil for glow plug relay
J11-7 Glow Plug / Ignition Control Relay Low side of the relay coil
Driver
J11-8 Magnetic Pickup Shield
J11-9 Magnetic Pickup Supply
J11-10 Magnetic Pickup Return
J11-11 Coolant Temperature Sender
J11-12 Coolant Temperature Sender Re-
turn
J11-13 NA
J11-14 NA
J11-15 NA
J11-16 NA
J11-17 ECM CAN Shield
J11-18 B+ Return for ECM
J11-19 ECM CAN Low
J11-20 ECM CAN High
J11-21 Keyswitch Low Side Driver Low side of keyswitch relay coil
J11-22 Keyswitch Relay Coil B+ High side of keyswitch relay coil
J11-23 NA
J11-24 NA

TABLE 3-8. J12 GENSET CT CONNECTIONS

Connector Pin Signal Name Connect To


J12-1 CT1
J12-2 CT2
J12-3 CT3
J12-4 CT1 Common
J12-5 CT2 Common
J12-6 CT3 Common

3-16
TABLE 3-9. J17 FIELD WINDING CONNECTIONS
Connector Pin Signal Name Connect To
J17-1 Field + X+ (F1)
J17-2 Field XX (F2)

TABLE 3-10. J18 FIELD POWER CONNECTIONS


Connector Pin Signal Name Connect To
J18-1 PMG 1 / Shunt L1 240 Vmax Excitation Source
J18-2 PMG 2 / Shunt L2 240 Vmax Excitation Source
J18-3 NC
TABLE 3-11. J20 GENSET CONNECTIONS
Connector Pin Signal Name Connect To
J20-1 Chassis ground
J20-2 B+ Return
J20-3 Switched B+ Low Side Driver
J20-4 B+ Return
J20-5 Discrete Input Return
J20-6 Discrete Input Return
J20-7 B+ Return
J20-8 Discrete Input Return
J20-9 B+ Input
J20-10 B+ Input
J20-11 Starter Disconnect Input Charging alternator
J20-12 B+ Return
J20-13 Relay Coil B+ Supply Switched B+ (Switched B+ might be connected to
EStop B+ instead)
J20-14 FSO Relay Driver Low Side of FSO Relay Coil
J20-15 Starter Relay Driver Low Side of Starter Relay Coil
J20-16 NA
J20-17 Configurable Input #3 Defaulted to Low Coolant Level Switch
J20-18 Configurable Input #4 Defaulted to Low Fuel Level Switch
J20-19 NA
J20-20 B+ Input
J20-21 B+ Input
J20-22 Alt Flash Input

TABLE 3-12. J22 GENSET VOLTAGE SENSING CONNECTIONS


Connector Pin Signal Name Connect To
J22-1 L1 600 Vmax L1 Source
J22-2 L2 600 Vmax L2 Source
J22-3 L3 600 Vmax L3 Source
J22-4 LN 600 Vmax LN Source

3-17
TABLE 3-13. J25 DISPLAY CONNECTIONS

Connector Pin Signal Name Connect To


J25-1 Local Status Low side of local status lamp
J25-2 Local E-Stop Normally closed local E-Stop switch
J25-3 PCCNet B Network Data B
J25-4 PCCNet A Network Data A
J25-5 System wakeup
J25-6 Discrete Input Return
J25-7 Discrete Input Return
J25-8 B+ Return
J25-9 B+ Return / PCCNet
J25-10 Manual
J25-11 Auto
J25-12 B+

TABLE 3-14. CONNECTOR PART NUMBERS

Connector Housing Connector Pins


Connector
CPG P/N Man/Man P/N CPG P/N Man/Man P/N
J11 3232161 Amp/Tyco / 7905871 3232466 Amp/Tyco / 7709041/
7709881/1716371
J12 3231932 Amp/Tyco / 14807040 3231200 Amp/Tyco / 3505361/3505501
J17 3232098 Amp/Tyco / 14806980 3231200 Amp/Tyco / 3505361/3505501
J18 3232444 Amp/Tyco / 14807000 3231200 Amp/Tyco / 3505361/3505501
J25 3232445 Amp/Tyco / 7705811 3232466 Amp/Tyco / 7709041/
7709881/1716371
J22 323222603 Amp/Tyco / 2828094
J20 3232466 Amp/Tyco / 7705861 3232466 Amp/Tyco / 7709041/
7709881/1716371

3-18
ELECTRONIC GOVERNOR The electronic fuel actuator is driven by the output
CONNECTIONS of the Governor Power Module. Use twisted pair
wires minimum 1 sq mm (16 Gage). Power to the
This section describes the installation of the option- Governor Power Module is derived from the genset
al Electronic Governor Power Module. starting battery but should be connected to the
Governor Power Module as indicated in the dia-
A description of the Governor Power Module con- grams Applications without FSO (see Figure
nections are listed in Table 3-15. Module connector 3-13) and Applications with FSO (see Figure
pat numbers are listed in Table 3-16. 3-14) as appropriate.

TABLE 3-15. GOVERNOR MODULE CONNECTIONS


Connector Pin Signal Name Comments
P1-1 Gov drive
P1-2 Gov drive +
P1-3 B+ Battery +
P1-4 Actuator Low side of actuator
P1-5 Return GND

TABLE 3-16. CONNECTOR PART NUMBERS FOR THE GOVERNOR MODULE CONNECTIONS
Connector Housing Connector Pins
Ref Internal P/N Man / P/N Internal P/N Man / P/N
P1 03232216 Amp/Tyco / 03231200 Amp/Tyco /
14807630 7700083

B+
EStop B+

Fuse

FSO
J2014

Relay
Governor
1302 Series Power Stage
Control Fuel
Actuator
J115
PWM

J114

GND

FIGURE 3-13. ELECTRONIC GOVERNOR CONNECTIONS FOR APPLICATIONS WITHOUT FSO

3-19
EStop B+

FSO B+
J2014
FSO
Relay
Governor
1302 Series Power Stage
Control

J115
PWM

J114

GND

FIGURE 3-14. ELECTRONIC GOVERNOR CONNECTIONS FOR APPLICATIONS WITH FSO


KIT INSTALLATION c. The negative () cable from the battery is
Refer to the control wiring diagram included in disconnected to prevent accidental start-
Section 7 when installing the items included in this ing.
kit. This wiring diagram also includes information
2. Select a suitable location (see Mounting
on wiring items (annunciator, I/O module, and gov-
Guidelines on page 3-1) and mount the
ernor power module) not included in this kit.
1302 control board using M4 hardware. Figure
While the harnesses included in this kit should be 3-15 shows the control board dimensions. The
long enough for all types of installations, it is a good outside dimensions do not include necessary
idea to make sure that the distance between two clearance for wire connections.
connecting parts does not exceed the length of the
harness. Excess wiring may be trimmed if it inter-
feres with your installation.
NOTE: To check the actual genset output, True
(calibrated) RMS meter should be
usedMounting hardware for the 1302 con-
trol and the operator panel is not included
in this kit. The instructions below include
suggested hardware sizes.

1. Make sure the generator set is shut down and


disabled:
a. The generator set Run/Off/Auto switch is
in the Off position and the generator is
cool (to the touch). DIMENSIONS ARE IN MILLIMETERS
b. The battery charger (if equipped) is
turned off and disconnected. FIGURE 3-15. 1302 CONTROL FOOTPRINT

3-20
3. Install the operator panel and operator panel
harness.

a. Select a suitable location and mount the


panel using #632 hardware. Figure 3-16
shows the operator panel dimensions.
The operator panel must be mounted
within 72 inches (1828.8 mm) of the con-
trol board.

b. Install the operator panel harness (see


Figure 3-17). Plug the P1 connector into
the display (either J1 or J2) and plug the DIMENSIONS ARE IN MILLIMETERS
P25 connector into the J25 connector on
the control board. FIGURE 3-16. OPERATOR PANEL FOOTPRINT

DIMENSIONS ARE IN FEET

FIGURE 3-17. OPERATOR PANEL HARNESS

3-21
4. Install the genset harness (see Figure 3-18). f. Connect the harness X+ and XX wires to
the generator field windings.
a. Make sure the current transformers in-
stalled are appropriate for use with a 1302 g. Make the connections for the excitiation
series control. Refer to the Guidelines for source (shunt or PMG). For shunt ap-
Current Transformers subsection, start- plications, connect J18-1 and J18-2 to the
ing on page 3-3. low side of L1 and L2. For PMG applica-
b. Make sure the battery charging alternator tions, connect J18-1, J18-2, and 18-3 to
installed is one of the types listed in the P2, P3, and P4 on the permanent magnet.
Battery Charger Alternator Connec- J18-1 and J18-2 are 240V maximum in-
tions subsection, starting on page 3-8. puts.

c. Make sure the alternator connections are CAUTION Do not connect J18-1 di-
appropriate for your installation (see Al- rectly to L1 in 480V applications. Mak-
ternator Connections on page 3-9). ing this connection will blow up the
d. Connect the six harness CT wires to the 1302 control board.
current transformers.
h. Connect the harness P12, P17, P18, and
e. Connect the four harness sense wires to P22 connectors to the mating connectors
the alternator. on the 1302 control board.

DIMENSIONS ARE IN INCHES

FIGURE 3-18. GENSET HARNESS

3-22
5. Install the engine harness. wires to the appropriate locations indi-
cated in Figure 3-19.
a. Connect the engine harness wires
marked P11-2 and P11-3 to the oil pres- NOTE: If your installation does not in-
sure harness wires marked J11-5, J11-6, clude an electronic governor, tie
and J11-17 (see Figure 3-20). back the wires marked P11-4 and
P11-5.
b. Connect the engine harness wires
marked P11-11 and P11-12 to the coolant e. Connect the engine harness P11 and P20
temperature sensor harness wires connectors to the 1302 control board J11
marked P11-11 and P11-12 (see Figure and J20 connectors.
3-21).
c. If installed, connect the engine harness 6. Install the oil pressure sensor and harness.
wires marked P11-8, P11-9, and P11-10
to the magnetic pickup sensor on the en- a. Install the sensor on the engine.
gine. If not installed, tie the wires back.
b. Connect the harness connector to the oil
d. Connect the remaining engine harness pressure sensor.

FIGURE 3-19. ENGINE HARNESS

3-23
DIMENSIONS ARE IN FEET

FIGURE 3-20. OIL PRESSURE SENSOR HARNESS

DIMENSIONS ARE IN FEET

FIGURE 3-21. COOLANT TEMPERATURE SENSOR HARNESS

FIGURE 3-22. OIL PRESSURE SENSOR

7. Install the coolant temperature sensor and


harness.
FIGURE 3-23. COOLANT TEMPERATURE SENSOR
a. Install the sensor on the radiator.
b. Connect the harness connector to the 11. Use the operator panel to access the Service
temperature sensor. menus (see Section 5) and/or a PC service
tool to adjust the appropriate control parame-
8. Reconnect the generator starting battery ters.
cables (positive [+] cable first).
a. For general information on all available
9. Connect the battery charger (If equipped).
parameters that can be adjusted, see
10. Press any button on the operator panel to Setup, Trims, and Adjustments on page
wake up the control. 3-26.

3-24
b. Follow the setup procedures for current 12V/24V batteries
transformers listed on page 3-4. Engine starting
c. For information on alternator control ad- Cycle cranking
justments, see page 3-36. Spark ignition power/Glow plug
d. For information on genset tuning, see control
page 3-36. Genset cooldown start and stop
time delays
e. For information on other control functions,
see page 3-46. These include: f. For information on the Battle Short option,
see page 3-55.
Remote start mode
12. Place the generator set Run/Off/Auto switch in
Remote emergency stop the desired position.

3-25
SETUP, TRIMS, AND ADJUSTMENTS of the Service menus that are used to ad-
just parameters using the 1302 operator
While applying a 1302 series control to a new ap- panel. The last column in Table 3-17 lists
plication, make sure the parameters listed in Table
the page references in Section 5 where you
3-17 have appropriate values. Many of these can
can find information on how to adjust each
be adjusted using the operator panel but some re-
parameter.
quire use of a genset Manufacturing Tool or a PC
based service tool. Configurable / Model Specific features like nominal
voltage, frequency, KVA rating, Engine protection
NOTE: To check the actual genset output, True values Alternator Protection values, AVR and Gov-
(calibrated) RMS meter should be ernor Gains, CT Ratio, etc have to be assigned ap-
usedSection 5 includes information on all propriate values at manufacturing time.

TABLE 3-17. 1302 CONTROL PARAMETERS


Adjusted Using Limits
Pg
Group Parameter Name PC Based Operator Upper Units
Lower Limit Ref
Service Tool Panel Limit
Adjust-
j Voltage Adjust X 5 5 %
ment Start Time Delay (V2.79 X X 0 300 Sec 5-8
and prior with HMI211 7.10
or prior)
Start Time Delay (V2.80 X X 0 3600 Sec 58
and later with HMI211 7.20
or later)
Adjust-
j Stop Time Delay X X 0 600 Sec 5-8
ment V/Hz Knee Frequency X X 0 10 Hz 5-17
V/Hz Rolloff Slope X X 0 5 % 5-17

3-26
TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)
Adjusted Using Limits
Pg
Group Parameter Name PC Based Operator Upper Units
Lower Limit Ref
Service Tool Panel Limit
Setup
p Nominal Battery Voltage X X 12 24 VDC 5-41
G
Genset AVR Enable X X Enable or NA NA 5-11
Disable
Excitation Source X X Shunt or PMG 5-39
Excitation / Line Frequency X X 1,2,4 5-39
Gain
Nominal Voltage X X 190 480 V AC 5-8
Alternator Nominal X X 50 or 60 N/A Hz 5-8
Frequency
Single Phase 60Hz Standby X X 0 2000 KVA 5-39
kVA Rating
Three Phase 60Hz Standby X X 0 2000 KVA 5-39
kVA Rating
Single Phase 50Hz Standby X X 0 2000 KVA 5-39
kVA Rating
Three Phase 50Hz Standby X X 0 2000 KVA 5-39
kVA Rating
Single Phase 60Hz Prime X X 0 2000 KVA 5-41
kVA Rating
Three Phase 60Hz Prime X X 0 2000 KVA 5-41
kVA Rating
Single Phase 50Hz Prime X X 0 2000 KVA 5-41
kVA Rating
Three Phase 50Hz Prime X X 0 2000 KVA 5-41
kVA Rating
Frequency to Speed Gain X X 20, 30, or 60 N/A RPM/Hz 5-39
Select
Oil Pressure Switch Polarity X Active Low or N/A N/A 5-43
Active High

3-27
TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)
Adjusted Using Limits
Pg
Group Parameter Name PC Based Operator Upper Units
Lower Limit Ref
Service Tool Panel Limit
Setup
p Oil Pressure Sensor Type X X 2 or 3 wire N/A N/A 5-43
G
Genset Electronic Governor Enable X Enable or NA NA
(Contin- Disable
ued)
X Yes or No N/A N/A 5-11
Glow Plug Enable X Enable or N/A N/A
Disable
X Yes or No N/A N/A 5-8
Fuel System X X Diesel or Gas N/A N/A 5-8
Fuel Burn Time Delay X X 0 10 Sec 5-8
Magnetic Pickup Enable X Enable or None N/A
Disable
X Yes or No None N/A 5-13
Flywheel Teeth X X 0 255 Teeth 5-39
Dither Factor X X 0 30 % 5-19
Maximum Governor Duty X X 0 100 % 5-19
Cycle
AVR Gain Adjust X X 5 1000 % 5-17
AVR K2 Gain Adjust X X 5 1000 % 5-17
AVR D Gain Adjust X X 95 105 % 5-17
K1 (Regulator Gain 50Hz) X 0 65535 NA
K1 (Regulator Gain 60Hz) X 0 65535 NA
K2 (Regulator Integral X 0 65535 NA
50Hz)
K2 (Regulator Integral X 0 65535 NA
60Hz)
K3 (Regulator K3 Gain X 0 65535 NA
50Hz)
K3 (Regulator K3 Gain X 0 65535 NA
60Hz)
Damping Effect (60Hz) X 0.2 0.99 NA
Damping Effect (50Hz) X 0.2 0.99 NA
Cycle Crank Attempts X X 1 7 Attempts 5-11
Cycle Crank Engage Time X X 3 30 Sec 5-11
Cycle Crank Rest Time X X 0 60 Sec 5-11
Remote / Local Display N/A X Remote or N/A N/A 5-15
Local
Battle Short Enable X Enable or NA NA 5-11
Disable
Battle Short Switch Input X X Configurable N/A N/A 5-11
input 14 or
operator panel
Governor Ramp Time X X 0 30 Sec 5-19

3-28
TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)
Adjusted Using Limits
Pg
Group Parameter Name PC Based Operator Upper Units
Lower Limit Ref
Service Tool Panel Limit
Setup ECM CAN Enabled X Disable, J1939,
ECM CAN PGI
Keyswitch Reset Delay X 1 10 Sec
Keyswitch On Time Delay X 1 10 Sec
CAN Datalink Failure X 0 10 Times
Retries
ECM Datasave Time X 30 60 Sec
Setup Configurable Input #14 X X Active open or N/A 5-21
Configur-
g Function Active closed
able
bl I/O Configurable I/P #1 X NO_ANNUN_M N/A 5-21
AnnActive LED APPING,
CUSTOMER_F
AULT_1,
CUSTOMER_F
AULT_2,
CUSTOMER_F
AULT_3,
GEN_SUPPLY
_LOAD,
CHARGER_AC
_FAIL,
LOW_COOLAN
T_LEVEL,
LOW_FUEL_L
EVEL
Configurable I/P #2 X NO_ANNUN_M N/A 5-21
AnnActive LED APPING,
CUSTOMER_F
AULT_1,
CUSTOMER_F
AULT_2,
CUSTOMER_F
AULT_3,
GEN_SUPPLY
_LOAD,
CHARGER_AC
_FAIL,
LOW_COOLAN
T_LEVEL,
LOW_FUEL_L
EVEL

3-29
TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)
Adjusted Using Limits
Pg
Group Parameter Name PC Based Operator Upper Units
Lower Limit Ref
Service Tool Panel Limit
Configurable I/P #3 X NO_ANNUN_M N/A 5-21
AnnActive LED APPING,
CUSTOMER_F
AULT_1,
CUSTOMER_F
AULT_2,
CUSTOMER_F
AULT_3,
GEN_SUPPLY
_LOAD,
CHARGER_AC
_FAIL,
LOW_COOLAN
T_LEVEL,
LOW_FUEL_L
EVEL

Configurable I/P #4 X NO_ANNUN_M N/A 5-21


AnnActive LED APPING,
CUSTOMER_F
AULT_1,
CUSTOMER_F
AULT_2,
CUSTOMER_F
AULT_3,
GEN_SUPPLY
_LOAD,
CHARGER_AC
_FAIL,
LOW_COOLAN
T_LEVEL,
LOW_FUEL_L
EVEL

3-30
TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)
Adjusted Using Limits
Pg
Group Parameter Name PC Based Operator Upper Units
Lower Limit Ref
Service Tool Panel Limit
Setup Configurable Fault Input X X Active open or N/A 5-21
Configur-
g #14 Active State Select Active closed
bl I/O
able Configurable Fault Input X X Warning, 5-21
#14 Fault Level Response Shutdown, or
None
Configurable #14 Input X X 5-21
Text Line 1
Configurable #14 Input X X 5-21
Text Line 2
Customer Output 1/2 Event X X 0 9999 Fault 5-25
Code
Numbers
Regulated Voltage Regulator X X 0.9 1.1 % 5-27
Voltage
g Calibration 50Hz
Adj t
Adjust Voltage Regulator X X 0.9 1.1 % 5-27
Calibration 60Hz
Alternator L1N 50Hz X X 0.8 1.1 % 5-27
Voltage Display Adjust
Alternator L2N 50Hz X X 0.8 1.1 % 5-27
Voltage Display Adjust
Alternator L2N 50Hz X X 0.8 1.1 % 5-27
Voltage Display Adjust
Alternator L1N 60Hz X X 0.8 1.1 % 5-27
Voltage Display Adjust
Alternator L2N 60Hz X X 0.8 1.1 % 5-27
Voltage Display Adjust
Alternator L2N 60Hz X X 0.8 1.1 % 5-27
Voltage Display Adjust
Alternator L1 50Hz Current X X 0.8 1.2 % 5-27
Adjust
Alternator L2 50Hz Current X X 0.8 1.2 % 5-27
Adjust
Alternator L2 50Hz Current X X 0.8 1.2 % 5-27
Adjust

3-31
TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)
Adjusted Using Limits
Pg
Group Parameter Name PC Based Operator Upper Units
Lower Limit Ref
Service Tool Panel Limit
Regulated Alternator L1 60Hz Current X X 0.8 1.2 % 5-27
Voltage
g Adjust
Adj t
Adjust Alternator L2 60Hz Current X X 0.8 1.2 % 5-27
(Contin- Adjust
ued)
Alternator L2 60Hz Current X X 0.8 1.2 % 5-27
Adjust
High AC Voltage Threshold X X 105 125 % 5-45
High AC Voltage Delay X X 1 10 Sec 5-45
Low AC Voltage Threshold X X 50 95 % 5-45
Low AC Voltage Delay X X 2 20 Sec 5-45
Under Frequency Threshold X X 2 10 Hz 5-45
Under Frequency Delay X X 500 2000 1/2 5-45
cycles
Overfrequency Enable X Enable or N/A NA
Disable
Overfrequency Threshold X X 2 10 Hz 5-45
Overfrequency Delay X X 100 2000 1/2 5-45
cycles
High AC Current Shutdown X X 2 60 Sec 5-45
Delay

Protection Overspeed Shutdown X X 0 8192 Rpm 5-49


Engine
g Threshold 50Hz
Overspeed Shutdown X X 0 8192 Rpm 5-49
Threshold 60Hz
LOP Shutdown Threshold X X 0 100 Psig 5-51
LOP Shutdown Delay X X 2 15 Sec 5-51
LOP Warning Threshold X X 0 100 Psig 5-49
LOP Warning Delay X X 2 15 Sec 5-49
LCT Warning Threshold X X 32 100 deg f 5-53
HCT Shutdown Threshold X X 180 300 deg f 5-51
HCT Shutdown Delay X X 2 10 Sec 5-51
HCT Warning Threshold X X 150 290 deg f 5-51
HCT Warning Delay X X 2 10 sec 5-51
12V Low Battery Threshold X X 11 13 VDC 5-41
24V Low Battery Threshold X X 22 27 VDC 5-41
Low Battery Fault Delay X X 2 60 Sec 5-43
High Battery Fault Delay X X 14 17 VDC 5-41
24V High Battery Threshold X X 28 34 VDC 5-41
12V High Battery Threshold X X 2 60 Sec 5-43
12V Weak Battery X X 6 10 VDC 5-41
Threshold

3-32
TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)
Adjusted Using Limits
Pg
Group Parameter Name PC Based Operator Upper Units
Lower Limit Ref
Service Tool Panel Limit
Protection 24V Weak Battery X X 18 21 VDC 5-41
Engine Threshold
(Contin-
ued) Weak Battery Fault Delay X X 1 5 sec 5-43
Fault Reset Runs X
Hi
History Reset Start Attempts X

NFPA 110 Status Logical Bits 17, Annunciator Configurable I/P# 2 Ann Active LED is applicable
Discrete Signals (Configurable via PCC1302 only for Configurable Input #2 Function.
A universal annunciator connected in a network in- Configurable I/P# 3 Ann Active LED is applicable
dicates and annunciates the active faults received only for Configurable Input #3 Function.
from the PCC1302. The NFPA 110 Status Logical Configurable I/P# 4 Ann Active LED is applicable
bits 1 to 7 (i.e. LEDs) of an annunciator can be only for Configurable Input #4 Trim Function
mapped to indicate and annunciate the active
faults corresponding to each of the four configur-
Each active fault corresponding to the respective
able inputs of PCC1302 as defined by the user. For
configurable input of PCC1302 is annunciated and
this, the (trim) Configurable Input #n Function (n =
indicated according to the LEDs mapped by the
1, 2, 3, or 4) should be set as Fault Input and the
LED should be mapped through (trim) Configur- user to the Configurable Input #n Function (n = 1,
able I/P# n Ann Active LED (n = 1,2,3 or 4), where, 2, 3, or 4) set as Fault Input:
Configurable I/P# 1 Ann Active LED) is applica- Refer the table below for more information on setup
ble only for Configurable Input #1 Function. and expected observations:

TABLE 3-18. 1302 CONTROL SETUP


Configurable I/P# n Ann
Active LED (n = Active Condition (LED# Active Fault Active
Input #
1,2,3 or 4) set to one of indication) on Annunciator Condition FC#
the following
Configurable
g In- NO_ANNUN_MAPPING No bit set = NONE None 1311
put #1
# Function
F i = CUSTOMER_FAULT_1 Bit 1 set = LED 1 Annunciator
Fault Input and Fault 1
Configurable
I/P# 1 Ann Active CUSTOMER_FAULT_2 Bit 1 set = LED 2 Annunciator
LED
LED Fault 2
CUSTOMER_FAULT_3 Bit 1 set = LED 3 Annunciator
Fault 3
GEN_SUPPLY_LOAD Bit 1 set = LED 4 Genset
Supplying
Load
CHARGER_AC_FAIL Bit 1 set = LED 5 Charger AC
Failure

3-33
TABLE 3-18. 1302 CONTROL SETUP (CONT.)
Configurable I/P# n Ann
Active LED (n = Active Condition (LED# Active Fault Active
Input # 1,2,3 or 4) set to one of indication) on Annunciator Condition FC#
the following
Configurable
g In- NO_ANNUN_MAPPING No bit set = NONE None 1312
F i = CUSTOMER_FAULT_1
put #1 Function Bit 1 set = LED 1 Annunciator
Fault Input and Fault 1
Configurable
I/P# 1 Ann Active CUSTOMER_FAULT_2 Bit 1 set = LED 2 Annunciator
LED
LED Fault 2
CUSTOMER_FAULT_3 Bit 1 set = LED 3 Annunciator
Fault 3
GEN_SUPPLY_LOAD Bit 1 set = LED 4 Genset
Supplying
Load
CHARGER_AC_FAIL Bit 1 set = LED 5 Charger AC
Failure
LOW_COOLANT_LEVEL Bit 1 set = LED 6 Low Coolant
Level
LOW_FUEL_LEVEL Bit 1 set = LED 7 Low Fuel
Level
Configurable
g In- NO_ANNUN_MAPPING No bit set = NONE None 1317
put #1
# Function
F i = CUSTOMER_FAULT_1 Bit 1 set = LED 1 Annunciator
Fault Input and Fault 1
Configurable
I/P# 1 Ann Active CUSTOMER_FAULT_2 Bit 1 set = LED 2 Annunciator
LED
LED Fault 2
CUSTOMER_FAULT_3 Bit 1 set = LED 3 Annunciator
Fault 3
GEN_SUPPLY_LOAD Bit 1 set = LED 4 Genset
Supplying
Load
CHARGER_AC_FAIL Bit 1 set = LED 5 Charger AC
Failure
Configurable
g In- NO_ANNUN_MAPPING No bit set = NONE None 1318
put #1 Function
F i = CUSTOMER_FAULT_1 Bit 1 set = LED 1 Annunciator
Fault Input and Fault 1
Configurable
I/P# 1 Ann Active CUSTOMER_FAULT_2 Bit 1 set = LED 2 Annunciator
LED
LED Fault 2
CUSTOMER_FAULT_3 Bit 1 set = LED 3 Annunciator
Fault 3
GEN_SUPPLY_LOAD Bit 1 set = LED 4 Genset
Supplying
Load
CHARGER_AC_FAIL Bit 1 set = LED 5 Charger AC
Failure

ALTERNATOR CONTROL ADJUSTMENTS The voltage regulation system is SCR type. Excita-
The 1302 series control includes an integrated line- tion power is derived either directly from the genset
to-line sensing voltage regulation system that is terminals or from a PMG stator. Power from either
compatible with shunt or PMG excitation systems. source is fed into the control thru J18. Positive volt-

3-34
age build up from residual levels is ensured by the protection of the excitation system, by reducing the
use of efficient semiconductors in the power circuit- output voltage proportionally with speed.
ry. The voltage rolloff set point and rate of decay (i.e.,
AVR Enable/Disable Feature the slope of the volts/hertz curve) is adjustable in
the control.
The 1302 series control provides automatic
voltage regulating capability for the generator set Major system features include.
when the AVR feature is enabled on the genset. It %Volts/Hz rolloff supports the engine speed
has a field adjustment trim to enable or disable the recovery under block loading. The slope set-
AVR feature. The trim parameter for this is AVR ting (%volts/Hz) range is 0.05.0% of rated
Enable = Enable / Disable. with 0.1% increment.
For information on enabling/disabling the AVR fea- The knee frequency range is 0.010.0Hz less
ture using the operator panel, see page 5-11. than the nominal frequency with 0.1 Hz incre-
ment.
Digital Output Voltage Regulation
For information on adjusting rolloff and knee fre-
The 1302 series control supports digital output quency settings using the operator panel, see page
voltage regulation as defined below. 5-17.
Voltage setpoint algorithm sets the level of the Battleshort Mode
automatic voltage regulation. It is adjustable.
The 1302 series control can be programmed to
The maximum allowed rated current for the work in battleshort mode by loading the battleshort
field coil for the regulation is 4.0 Amps RMS feature with a manufacturing tool or PC based ser-
and maximum 6.0 Amps for 10 seconds. vice tool.
The control provides voltage ramping at start- The controller then can accept Configurable Input
up if the AVR algorithm is enabled, such that 14 as battle short switch inputs. If an operator
voltage overshoot can be controlled. AVR boot panel is used, it can be also selected as a source of
enable logic supports the step by step voltage input by selecting appropriate input source value
ramping. for the trim.
A PC based service tool allows the operator to Battleshort mode is designed to work only in critical
adjust the output voltage within plus or minus load circumstances. While in battleshort mode the
5.0% of rated voltage. 1302 series control will ignore most warnings and
shutdowns and will continue to operate as if no fault
Torque-Matched Volts/Hz Overload or shutdown exists on the system.
Control
For information on enabling/disabling the battle-
A frequency measuring circuitry monitors the short feature using the operator panel, see page
generator output and provides output underspeed 5-11.

3-35
GENSET TUNING justment points are the V/Hz Knee Frequency
which set the point at which the V/Hz curve starts,
The 1302 series control uses a standard 4 coeffi-
and the V/Hz Rolloff Slope which sets the rolloff
cient PID algorithm running at an execution rate of
slope of the voltage setpoint as a function of fre-
once per zero cross of the generator AC waveform.
quency error.
Standard values for the K1K4 and damping terms
for both 60 and 50Hz are listed in Table 3-19. The default V/Hz settings are:
Consider the following before making any adjust- Parameter Default Value
ments. V/Hz Knee Frequency 0.5 Hz
The values of K3, K4, and the damping factor V/Hz Roll-off Slope 2.2 %V/Hz
are set for basic stability reasons and should The voltage set point command is calculated from
not need to be adjusted, but they can be ad- the frequency error between commanded frequen-
justed if necessary. cy and the actual frequency. For example, a volt-
The useful range of values for K2 is 200 to age set point of 93.4% of nominal would be com-
1500. The value of 1500 for K2 can be a little manded if there is a frequency error of 3.5Hz under
too high or aggressive for some applications nominal. There is no offset to voltage for errors
and cause ringing upon recovering from a above nominal frequency.
load acceptance or offload transient situation.
NOTE: To check the actual genset output, True
A value of K2 below 200 can cause the regula-
(calibrated) RMS meter should be
tor to hit an integrator windup limit and should
usedNote: There are only one V/Hz set-
be avoided if possible. Set the correct value for
tings per calibration so the values must be
the application.
used for both 50 and 60Hz operation. If a
The value of K1 should be adjusted to meet the particular application requires vastly differ-
specification for percent off rated voltage dur- ent V/Hz settings for 50Hz and 60Hz op-
ing a load acceptance, and prevent large volt- eration, it will be required to create sepa-
age overshoots during offloads and during en- rate software features for those applica-
gine/alternator startup. tions.
The value of K2 should be adjusted to control
the recovery characteristics of the voltage dur- For information on how to adjust the slope and
ing large load acceptance and rejection tran- knee frequency using the operator panel, see page
sients. Values of K2 which are too high can 5-17.
cause unstable voltage performance and val-
ues too low can cause slow performance or TABLE 3-19. GOVERNOR GAINS FOR SMALL
steady state voltage offset errors. ENGINES
In general, K1 increases and K2 decreases in val- Newage BC/UC Generators Under 200Kw
ue with increasing generator size, but can vary in
60Hz 50Hz
different applications.
K1 = 1000 K1 = 1000
V/Hz Curve K2 = 650 K2 = 650
The 1302 series control uses a simple breakpoint K3 = 10000 K3 = 10000
and slope approach to the V/Hz curve to allow for
K4 = 36429 K4 = 36429
the matching of the torque curve of the engine dur-
ing a large transient load acceptance. The two ad- Damping = 0.8 Damping = 0.8

3-36
Governor justed first to allow the engine to be transitioned
smoothly into this) and adjusting GK3 until the best
The 1302 series controls governor also uses the 4
performance is observed, then doing the same for
coefficient PID algorithm. There are gains for use
the Damping factor. Repeat this process at least
at 50 and 60Hz operation. Standard values for the
once to ensure that the best possible values for
K1K4 and damping terms for both 60 and 50 Hz
GK3 and the Damping term have been determined.
for engines in the Cummins 4B3.9 and 6B5.9 range
are listed in Table 3-20. For information on how to adjust the GK1and GK2
values and the damping factor using the operator
panel, see page 5-17.
TABLE 3-20. GOVERNOR GAINS FOR SMALL
ENGINES Engine Startup
The 1302 series control applies fuel to the engine
60Hz 50Hz
as described in the Speed Governor Algorithm and
GK1 = 1696 GK1 = 1200 Adjustment section.
GK2 = 240 GK2 = 300 Alternator Startup
GK3 = 28,800 GK3 = 28,800 The alternator will be started up and brought to
GK4 (calc) = 7424 GK4 (calc) = 7424 rated voltage when the engine speed reaches
rated speed. The PWM command to the field coil
Governor Damping = Governor Damping = will now be stepped through an AVR Boot Table un-
0.936 0.936 til the sensed voltage goes above the value of the
AVR Boot Threshold trim and if AVR feature is en-
Governor Tuning
abled. The regulator will now bring the voltage up to
A good starting point for any new engine applica- rated voltage.
tion is to start with a set of released gains for an en- The purpose of the AVR Boot Table is to aid alterna-
gine of a similar type and size should they already tor startup whilst preventing overvoltage condi-
exist. tions. The value of the AVR Boot Table and the AVR
If a set of predeveloped gains are not available, Boot Threshold can be set to bring the voltage up
the gains listed above should work well enough to both as quickly and as smoothly as possible, but
start most engines and to allow them to run should already be set in the calibration to their ideal
smoothly. values. The AVR Boot Table has different values
The value of GK1 should be adjusted to meet the depending on value of the Excitation Source trim.
specification for percent off rated voltage during a Setup for Gain Tuning
load acceptance, to prevent large voltage over-
In order to properly set up engine and alternator
shoots during offloads, and during engine/alterna-
control parameters it is convenient to setup the PC
tor startup.
based service tool to be used to monitor.
The value of GK2 should be adjusted to control the The following are step-by-step procedures for de-
recovery characteristics of the engine during large termining engine and alternator control parame-
load acceptance and rejection transients. GK2 is a ters.
true integral type gain and is applied to the gover-
nor output as GK2 times the sum of all the previous 1. Determine 60Hz governor gains, regulator
governor error. Values of GK2 which are too high gains, and V\Hz curve values with PMG ex-
can cause unstable voltage performance and val- citation.
ues too low can cause slow performance or steady a. Start the genset, bring it to rated speed
state voltage offset errors. and temperature, and adjust the GK3 and
The values of GK3, GK4 and the Damping factor damping factor for 60Hz operation to al-
are used to set the basic steady state stability of the low the engine to run smoothly in steady
engine, but also influence the overall speed of re- state operation.
sponse of the governor in transient situations. Ad-
justment of GK3 and the Damping factor is an itera- NOTE: GK1 and/or GK2 may need to be
tive process started by finding the engine load level adjusted to allow this to happen.
which produces the worst steady state engine per- Apply various loads up to 100% rated and
formance (note: GK1 and GK2 may have to be ad- verify the steady state operation at all load

3-37
levels. Most engines have some load lev- speed very poorly. A V/Hz curve too shal-
el which is inherently less stable than oth- low causes a very slow engine recovery
ers and must be found to determine the from a transient.
correct value for GK3 and the damping
factor. c. Re-verify steady state voltage and gover-
nor performance.
NOTE: It is important to control the 2. Determine 50Hz governor gains, Regulator
steady state performance of the gains, and V/Hz curve values. Follow the
engine. Unstable engine perfor- same process as used at 60Hz. The order of
mance is carried over into the 50Hz vs 60Hz testing can be reversed.
generator output voltage. Very
fast increases or decreases in en- 3. Determine the correct values for the governor
gine speed, even if the magnitude startup parameters (see Speed Governor Al-
of the increase or decrease is gorithm and Adjustment below).
small, tend to be carried into the
alternator voltage as large in- a. Adjust the Initial Crank Fueling Com-
creases and decreases in voltage mand, Initial Crank Fueling Period, Crank
at the same frequency as the en- Fueling Ramp Rate, and Max Crank Fuel-
gine speed changes. ing Command parameters to control the
way the engine transitions through the
b. Do a series of load steps to determine the cranking stage of the engine startup. The
transient characteristics of the genset. controls default values should work well.
Tuning of the governor GK1 and GK2 val-
b. The value of the Crank Exit Fueling Com-
ues, the settings of the V/Hz curve, and
mand parameter should be set to the gov-
the values of K1 and K2 (mostly K1) for
ernor duty at which the engine runs when
the regulator must be done concurrently.
at rated speed, or to a value slightly high-
In general, these values should be ad-
er.
justed to achieve the maximum possible
performance from both the engine and Gain Tuning Parameters
the alternator. A production test spec (if
This is a list of all of the parameters which affect
available) should give the full load step
genset performance. A correct value should be de-
transient performance levels for any giv-
termined for each of the parameters listed.
en genset model. This is a very iterative
process and many require some time to NOTE: To check the actual genset output, True
find the best combination of gains to fit the (calibrated) RMS meter should be
application. In general, adjust GK1 to con- usedFor any parameters that have some-
trol the peak frequency during transients thing listed in the Value column, it is
and adjust GK2 to control the recovery recommended that the parameter stay at
shape of the frequency transient. A V/Hz that value during testing. Some parame-
slope too steep causes the engine to re- ters should never be changed during test-
cover too quickly and recovers to nominal ing and are listed as never to be changed.

3-38
TABLE 3-21. GAIN TUNING PARAMETERS
Parameter Value Comments
AVR Parameters
K1 (50Hz) Sets overall AVR gain in 50Hz applications. This is a true
proportional gain which is multiplied against the voltage
error signal.
K2 (50Hz) Controls the recovery shape of voltage transients in 50Hz
applications. This is a true integral gain which is multiplied
against the sum of all previous errors.
K3 (50Hz) Affects high frequency characteristics of the AVR algorithm
in 50Hz applications. Adjust for voltage stability reasons.
Damping Effect (50Hz) Affects high frequency characteristics of the AVR algorithm
in 50Hz applications. Adjust for voltage stability reasons.
K1 (60Hz) Sets overall AVR gain in 60Hz applications. This is a true
proportional gain which is multiplied against the voltage
error signal.
K2 (60Hz) Controls the recovery shape of voltage transients in 60Hz
applications. This is a true integral gain which is multiplied
against the sum of all previous errors.
K3 (60Hz) Affects high frequency characteristics of the AVR algorithm
in 60Hz applications. Adjust for voltage stability reasons.
Damping Effect (60Hz) Affects high frequency characteristics of the AVR algorithm
in 60Hz applications. Adjust for voltage stability reasons.
Engine Governing Parameters
GK1 (50Hz) Sets overall governor gain in 50Hz applications. This is a
true proportional gain which is multiplied against the fre-
quency error signal.
GK2 (50Hz) Controls the recovery shape of speed transients in 50Hz
applications. This is a true integral gain which is multiplied
against the sum of all previous errors.
GK3 (50Hz) Affects high frequency characteristics of the governor algo-
rithm in 50Hz applications. Adjust for frequency stability
reasons.
Governor Damping Effect Affects high frequency characteristics of the governor algo-
(50Hz) rithm in 50Hz applications. Adjust for frequency stability
reasons.
GK1 (60Hz) Sets overall governor gain in 60Hz applications. This is a
true proportional gain which is multiplied against the speed
error signal.
GK2 (60Hz) Controls the recovery shape of frequency transients in
60Hz applications. This is a true integral gain which is mul-
tiplied against the sum of all previous errors.
GK3 (60Hz) Affects high frequency characteristics of the governor algo-
rithm in 60Hz applications. Adjust for frequency stability
reasons.
Governor Damping Effect Affects high frequency characteristics of the governor algo-
(60Hz) rithm in 60Hz applications. Adjust for frequency stability
reasons.

3-39
TABLE 3-21. GAIN TUNING PARAMETERS (CONT.)
Parameter Value Comments
Engine Starting Parameters
Initial Crank Fueling Duty The initial value assigned to Governor Duty Cycle at entry
Cycle in Crank State
Initial Crank Fueling Period The period for which the value of Initial Crank Fuel Duty
Cycle is assigned to Governor Duty Cycle after entry in
Crank State
Crank Fueling Ramp Rate The Rate at which the value of Governor Duty Cycle is
ramped up by during Crank State after expiration of the
Initial Crank Fueling Period
Maximum Crank Fueling The level to which the Governor Duty Cycle is limited dur-
ing Crank State
Crank Exit Fueling The Value at which the Governor Duty Cycle is held after
Command disengaging the starter until the Governor is enabled.
Governor Enable Speed The Value of speed above which the electronic governor
starts controlling the value of Governor Duty Cycle
Governor Ramp Time Sets the minimum governor speed reference ramp rate

3-40
Controller Calibration Voltage measurement for regulation
The internal circuitry of the 1302 series control may Current measurement for display
need to be calibrated. There are three different
components which may need this. They are: The internal circuits must be calibrated in the order
Voltage measurement for display listed in Table 3-22.
TABLE 3-22. CONTROLLER CALIBRATIONS FOR GENSETS
Component to be Calibration Method
Calibrated PC Based Service Tool Operator Panel
Voltage Measurement for 1. Connect to the control with your PC 1. View the Service Menu by holding
Regulation based service tool. down the up and down arrow keys
The goal of this is to cali- on any of the operator menus (see Fig-
2. Verify the Nominal Voltage Trim is
brate the regulation cir- ure 3-24).
set to the desired value.
cuitry so it regulates the 2. Select item 1, Setup Menus.
genset to the desired 3. Adjust the trim Voltage Regulation
3. Enter setup menu password 574.
nominal voltage. Calibration 50Hz or Voltage Regu-
lation Calibration 60Hz for your 4. Select item 1, Genset Service.
desired application. The effect of 5. Select item 1, and verify the Volts AC
this trim is inverse on the regu- setting is correct for your application.
lated voltage. Increasing the trim, If necessary, press the Adjust button
and change the setting. and press the
well lower the regulated voltage, Save button.
and decreasing the trim will raise
the regulated voltage. Adjust the 6. Press the back button to return to the
service menu.
trim so regulated voltage matches
the desired nominal voltage mea- 7. Select item 3, Meter Calib.
sured with a known calibrated 8. Press the Adjust button and change
voltage meter. the Reg Volt Adj: value. The effect of
this trim is inverse on the regulated
4. Save the adjustments by doing a voltage. Increasing the percentage will
Save Trims with your PC based decrease the regulated voltage. De-
service tool. creasing the percentage will increase
the regulated voltage.
9. Save the adjustments by pressing the
Save button.
Voltage Measurement for 1. Connect to the control with your PC 1. View the Service Menu by holding
Display based service tool. down the up and down arrow keys
2. Verify the Nominal Voltage Trim is set on any of the operator menus (see Fig-
to the desired value. The trim Alterna- ure 3-25).
tor Nominal Voltage is available at Ad- 2. Select item 1, Setup Menus.
justments AC Measurement Cal- 3. Enter setup menu password 574.
ibrations Voltage Measurement for
Regulation. Set the Alternator Nomi- 4. Select item 1, Genset Service.
nal Voltage to the voltage that the gen- 5. Select item 3, Meter Calib.
set will generate.
6. Press the down arrow twice to scroll
3. Adjust the trim Alternator LXN 50Hz down to the Metering Voltage Adjust
Voltage Display Adjust or Alternator
LXN 60Hz Voltage Display Adjust 7. Adjust the three parameters listed so
trim for your application. Each line will the display voltage matches the volt-
need to be adjusted independently. age being produced by the genset.
The goal is to have the value read by 8. Save the adjustments by pressing the
the PC based service tool correspond save button.
to the actual voltage being produced.
4. Save the adjustments by doing a Save
Trims with your PC based service tool.

3-41
TABLE 3-22. CONTROLLER CALIBRATIONS FOR GENSETS (CONT.)
Component to be Calibration Method
Calibrated PC Based Service Tool Operator Panel
Current Measurement for 1. Apply a load to the genset and monitor 1. View the Service Menu by holding
Display the current with a calibrated current down the up and down arrow keys
meter. on any of the operator menus (see Fig-
2. Connect to the control with your PC ure 3-26).
based service tool. 2. Select item 1, Setup Menus.
3. Verify the CT ratio settings and power 3. Enter service menu password 574.
ratings are correct for your application. 4. Select item 2, Genset Setup.
The Power Rating of the alternator is
configurable with the trims located in 5. Enter the setup menu password 1209.
Genset Power Ratings menu. The CT 6. Verify with the display that the CT ra-
ratio adjustable trim is available at tios and power rating are correct by
Features Genset Setup. scrolling through the available
4. Adjust the LX 50Hz Current Adjust or screens.
LX 60Hz Current Adjust trim for your 7. Return to the Setup Menu screen by
current application so the 1302 series press the back arrow twice.
control measured current matches the
current read by the know current me- 8. Select item 1, Genset Service.
ter. Each of the three lines will have to 9. Select item 3, Meter Calib.
be adjusted independently of each 10. Press the down arrow three times to
other. scroll down to Metering Current Ad-
5. Save the adjustments by doing a save just.
trims with your PC based service tool. 11. Adjust the three parameters to match
the current being displayed by the
known current meter.
12. Save the adjustments by pressing the
Save button.

3-42
NOTE: THE NUMBERS IN PARENTHESIS (1)
MATCH THE STEPS INCLUDED
IN THE PROCEDURE LISTED IN
TABLE 3-22.

(2)

(3)

ENTER 574

(4)

(5)

(5) (7)

(6)
(5) (8)
ENTER VOLTS ENTER REG
AC VALUE AND VOLT ADJ VALUE
PRESS THE AND PRESS THE
SAVE BUTTON SAVE BUTTON

(5) (9)

FIGURE 3-24. OPERATOR PANEL MENUS FOR CALIBRATING VOLTAGE MEASUREMENT FOR REGULA-
TION

3-43
(1) NOTE: THE NUMBERS IN PARENTHESIS
MATCH THE STEPS INCLUDED
IN THE PROCEDURE LISTED IN
TABLE 3-22.

(2)

(3)

ENTER 574

(4)

(5)

(6) (7)

(6) (7) ADJUST ALL THREE


PARAMETERS AND
PRESS THE SAVE
BUTTON

(8)

FIGURE 3-25. OPERATOR PANEL MENUS FOR CALIBRATING VOLTAGE MEASUREMENT FOR DISPLAY

3-44
(1) NOTE: THE NUMBERS IN PARENTHESIS
MATCH THE STEPS INCLUDED
IN THE PROCEDURE LISTED IN
TABLE 3-22.

(2)

(9) (3)
ENTER
574

(10) (4)

(8)
(7) (6)

(10)

(5)
ENTER
1209

(10) (6)

(6)

(10) (6)

(6)

(6)
(11)

ADJUST ALL THREE


PARAMETERS AND
PRESS THE SAVE
(12) BUTTON

FIGURE 3-26. OPERATOR PANEL MENUS FOR CALIBRATING CURRENT MEASUREMENT FOR DISPLAY

3-45
1302 CONTROL FUNCTIONS switched B+) when an emergency stop is active. In
order to do this, add a second E-stop contact in se-
Remote Start Mode ries with B+ and the FSO relay coil. Figure 3-27 il-
The 1302 series control accepts a ground signal lustrates one possible way to do this. Power to the
from remote devices to automatically start the fuel shutoff valve is provided serially through one
generator set and immediately accelerate to rated contact of the two contact E-stop switch. The con-
speed and voltage. The control can incorporate a nection point is called EStop B+.
time delay start. Referring to wiring diagram: 6303270 for com-
For information on how to set a start time delay plete illustration.
using the operator panel, see page 5-8.
12/24V Battery
Remote Emergency Stop
For operation of the genset, a closed relay contact The 1302 series control provides 12 and 24 VDC
between TB1-15 and TB1-16 must be present. The battery operation capability for genset system. It
control enters an emergency stop mode when the requires battery voltage input from the genset
short is removed. Before the genset can be starter batteries.
restarted, the control must be manually reset by The control system provides a field adjustable trim
re-applying the short and acknowledging the fault. to select either 12V/24V battery operations for
The E-stop circuit contains two parallel paths. One selection of the internal thresholds to this feature.
path is fed into the micro-processor for status The trim parameter for this is Nominal Battery Volt-
processing. The second path is fed directly into the age and the default trim is set at 12 VDC.
relay drivers, disabling them when an E-stop is
For information on how to set the nominal battery
present.
voltage using the operator panel, see page 5-41.
Local Emergency Stop
Engine Starting
For operation of the genset, a short between J25-2
and J25-6 must be present. The control enters an The control system supports automatic engine
emergency stop mode when the short is removed. starting. Primary and backup start disconnects are
Before the genset can be restarted, the control achieved by one of the following three methods:
must be manually reset by re-applying the short magnetic pickup, battery charging alternator
and acknowledging the fault. The E-stop circuit feedback, or main alternator output frequency.
contains two parallel paths. One path is fed into the
Cycle Cranking
micro-processor for status processing. The sec-
ond path is fed directly into the relay drivers, disab- The 1302 series control can be configured for the
ling them when an E-stop is present. number of starting cycles (1 to 7) and duration of
crank and rest periods. The control includes starter
Emergency Stop protection algorithms to prevent the operator from
It is also required that there be a physical interrup- specifying a starting sequence that might be
tion of the FSO and the starter (and, optionally, damaging.

Local Local Remote


EStop EStop EStop
Contact 1 Switch Contact 1

Remote 1302 Series Control


EStop
Switch

Local
B+ EStop Remote EStop B+
Contact 2 EStop (To Relay
Contact 2 Contacts)

FIGURE 3-27. EMERGENCY STOP CONTACTS

3-46
For information on how to set the cycle crank Total Glow Time respectively based on reading of
attempts using the operator panel, see page 5-11. Engine Coolant Temperature as shown in the
graph above. Cranking will start after the Preheat
Spark Ignition Power/Glow Plug Control Time has expired. The Glow Plug Output will re-
Pin J11-7 on the 1302 series control is dual main on until the Total Glow Time has expired. The
purpose. Control commands the glow plugs to enable when
the control.
Glow Plug Control
a. Detects that the genset has received a
Glow plug is used as a Cold starting aid. Glow plugs valid start command.
heat up the air going in for combustion for Diesel
Engine. Glow plug is used to improve the starting b. Determines teh preheat time and total
ability of engines and to reduce the white smoke glow times as the function of the Engine
during cold start. Coolant Temperature.
In PCC1302 when Glow Plug Enable = Enabled c. Turns off the glow plug during the normal
and Fuel System = Diesel the Glow Plug Function
stop or during the fault shutdown or during
is enabled and control will preheat the engine
the cyclical crank attempts or if the total
starting glow plugs. Pin J117 on the PCC1302
glow time has expired.
control can be used to drive Glow Plugs via
external Relay.
Preheat Processing
Setting Glow Plug Enable = Disabled or Fuel
System = Gas, disables the Glow Plug Function. Preheat processing logic has three associated
trims as shown in Table 322

TABLE 3-23. PREHEAT PROCESSING TRIMS


TABLE
Sr. No Name of the Default Range
Trims Value
Preheat Time 15 (sec) 030 (sec)
1
(Trim)(sec)
Preheat Tem- 70 (_F) 0100 (_F)
2 perature
(Trim)(_F)
Preheat Knee 0 (_F) 070 (_F)
3 Point
(Trim)(_F)
Preheat Time = controls how many seconds the
glow plug will preheat before cranking the engine.
FIGURE 3-28. PREGLOW MEASUREMENT
Preheat Temperature = controls at which temper-
Glow Plug Control implemented in PCC1302 con- ature the control defines a noncold engine. The
sists of the following two processes: glow plugs will not preheat for engine coolant tem-
a. Preheat Process (PreGlow Process) peratures above the Preheat Temperature.

b. Total Glow Process Total Glow Processing:


Preheat Glow Time and Total Glow Time are deter- Total Glow processing logic has three associated
mined by linear interpolation of Preheat Time and trims as shown in Table 323.

3-47
TABLE 3-24. TOTAL GLOW PROCESSING TRIMS neously with the fuel solenoid and held on as long
TABLE as the genset is running. Both drivers stay on while
Sr. No Name of the Default Range the engine speed is above 150 RPM. When a shut-
Trims Value down command is received, the fuel solenoid is
disabled but the ignition control module driver
Total Glow 0 (sec) 060 (sec)
1 Time
stays on until the Fuel Burn Off Time delay timer ex-
(Trim)(sec) pires. By running the ignition system off of this
delayed output, all of the fuel downstream of the
Total Glow 70 (_F) 0110 (_F)
fuel solenoid is burned following a genset stop /
2 Temperature
(Trim)(_F)
shutdown. This removes the occasional fuel flash
in the exhaust system after a stop / shutdown.
Total Glow 0 (_F) 032 (_F)
3 Knee Point Refer to the wiring diagram for more information on
(Trim)(_F) how to configure the Remote Emergency Stop
Switch for gas gensets to interrupt the ignition sys-
Glow Plug Output Logic: tem power.
In PCC1302, Glow Plug Output depends upon To- For information on how to set the Fuel Type, enable
tal Glow Time Value (Mon). The Glow Plug Output a Glow Plug, and set a Fuel Burn Time Delay using
turns on when Fuel System (Trim) = Diesel and To- the operator panel, see page 5-8.
tal Glow Time Value (Mon) > 0. Glow Plug Driver Start and Stop Time Delays (Cool Down)
Command remains on until the Total Glow Time
Value (Mon) has expired. Glow Plug Output turns The 1302 series control is configurable for a time
off, if any of the following conditions is valid: delay of 0300 seconds prior to starting after
a. When Total Glow Tiem Value (Mon) ex- receiving a remote start signal, and for a time delay
of 0600 seconds prior to shut down after signal to
pires.
stop in normal operation modes. The default for
b. When Generator Set Control stops nor- both time delay periods is 0.
mally. 03600 seconds (fron 1302 calibration version
2.80 and HMI211 calibration version 7.20). Earlier
c. When Generator Set Control stops during
versions have 0300 seconds.
emergency.
For information on how to set a start or stop time
d. When Generator Set Control performs cy- delay using the operator panel, see page 5-8.
clical crank process.
Electronic Governor
When the trim parameter Fuel Type is set to Diesel
and Glow Plug is Enabled, the control preheats the The 1302 series control provides electronic gov-
engine starting glow plugs. Two trim parameters erning capability for a generator set when a elec-
may need to be adjusted in order for the glow plug tronic governor option is installed on the genset. It
preheat control logic to work effectively. The trim has a field adjustment trim to enable or disable the
parameter Preheat Time = seconds controls how electronic governing feature. It supports isochro-
many seconds the glow plugs will preheat before nous speed governing as defined below.
cranking the engine. The trim parameter Preheat The maximum allowed rated current for the
Temperature = degrees Fahrenheit controls at actuator drive for the governor power stage is
which temperature the control defines a non-cold 6.0A continuous max; 10 Amps for 1 second.
engine. The glow plugs will not preheat for engine
coolant temperatures above the Preheat Tempera- The governing system is suitable for use with
ture. Adjusting both of the trims will allow for tailor- Gensets using Cummins EFC normally closed
ing of the glow plug preheat logic for specific en- actuators, Woodward, FORD Gas, or Barber-
gine applications. Setting Glow Plug = Disabled Coleman actuators with similar drive charac-
disables the glow plug preheat logic. teristics.
When the trim parameter Fuel Type = Gas, pin It provides speed governor setpoints of 1500
J11-7 can be used to control an external spark igni- RPM and 1800 RPM. The governor setpoint is
tion control module. Pin J11-7 is turned on simulta- a field adjustment (50 Hz or 60 Hz).

3-48
The optional display allows the operator to ad- vent the fuel actuators from becoming stuck.
just frequency within plus or minus 5% of rated Therefore dither should be used in applica-
speed. tions where the fuel actuators are prone to
sticking. This feature has adjustable dither
The controller provides ramping at startup and amplitude (0% to 30% of governor duty cycle).
an ability to program the cranking fueling be- The dither function is enabled by selecting a
fore the governor algorithm is enabled. dither factor. The dither function is disabled by
setting the dither factor to 0%.
Engine Speed Sensing
The following cranking fuel control characteristics
For electronically governed gensets, the 1302 se- are also provided to tune up the genset startup to
ries control requires an engine speed input from a suit the application. Cold weather applications
magnetic pickup speed sensor. The magnetic pick- might need a longer cranking period and/OR high-
up signal needs to be calibrated for number of en- er levels of cranking fuel. Following parameters
gine flywheel teeth. The table shown below lists the should be chosen to make sure the genset starts
number of flywheel teeth for some common engine up quickly enough but does not overshoot or pro-
types. duces excessive smoke at startup.
TABLE 3-25. FLYWHEEL TEETH REQUIREMENTS The initial cranking fuel duty cycle can be cho-
Number of sen to suit the engine / application.
Engine Type
Flywheel Teeth
The initial cranking fuel period can be chosen
Cummins 4B, 6B 159
to suit the application.
Cummins 4C 138
Ford 4cycl Gas 104 The cranking fuel is ramped up during crank-
ing after initial cranking fueling period is over.
Kubota Engines 105 The rate of ramping up of fueling can be cho-
Cummins L10, NT855 118 sen to suit the application.
Komatsu 3.3L 110
The maximum crank fuel duty cycle can be
Cummins V28, K19, 142 chosen to suit the application. During cranking
K38, K50 the duty cycle of the PWM, output to the actua-
Ford V6 and V10 gas 133 tor will be limited to this value.

The crank exit fuel duty cycle can be chosen


For non-electronically governed gensets, the mag-
to suit the application. After the engine fires,
netic pickup is optional. If it is not used, engine
the fueling level will return to this value before
speed is calculated from the alternator output fre-
the 4 coefficient algorithm takes over the con-
quency.
trol of the PWM output to the actuator.
Speed Governor Algorithm and Fueling is initially set to the Initial Crank Fueling
Adjustment Duty Cycle value and remains at that value for the
Initial Crank Fueling Period. After this period ex-
The 1302 series control supports the following pires, the fuel command is ramped at the Crank
speed governor algorithm characteristics: Fueling Ramp Rate until the Maximum Crank Fuel-
ing limit is reached. Upon reaching the Starter Dis-
It uses a four-coefficient field adjustable connect Speed, the fueling command is pulled
closed loop PID control algorithm (Proportion- back to the Crank Exit Fueling Duty Cycle value un-
alIntegralDerivative). til the Governor Enable Engine Speed is reached.
It allows field tuning of the speed coefficients. When the Governor Enable Engine Speed is
reached, the governor is enabled, the speed set-
The 1302 series control provides a dither fea- point is set to the sensed engine speed value at this
ture. Dither is a method of introducing small point, and the setpoint is ramped to rated speed in
amounts of noise into the speed governing a time equal to the Governor Ramp Time. The dia-
system. The purpose of this feature is to pre- gram below illustrated these setpoints.

3-49
Crank Fuel Duty Cycle Closed Loop Operation

Max Crank Fuel


Duty Cycle

Initial Crank Fuel


Duty Cycle

Crank Exit Fuel


Initial Crank Duty Cycle
Fueling Period

Crank Fuel
Ramp Rate

FIGURE 3-29. GOVERNOR RAMP TIME SETPOINTS


REAL TIME CLOCK (MM/DD/YY) for Date and AM for Clock Cycle. Un-
der this condition, and with Scheduler Prog x En-
The PCC1302 control system includes a Real Time able trim Enabled and Clock Diagnostic Enable
Clock (RTC) function used for automatic scheduler trim Enabled, FC 1689 (Clock Not Set) will become
(exercise scheduler) feature. The Real Time Clock active indicating that the date, time and AM/PM
(RTC) in PCC1302 is NOT used for calculating needs to be set by the user.
controller on time, or for recording fault occurrence The RTC also supports Daylight Savings Time
times, or for supporting factory test. Once (DST), which is a convention used to advance the
PCC1302 is programmed and given a power cycle, time by one hour so that afternoons have more
the user should enter the correct time, date and daylight than mornings. The DST logic adds the
clock cycle (AM/PM). Based on the time and date DST Adjustment time to the current time when the
saved by the user, the real time clock accurately* current time is equal to the DST Start Time. The
calculates seconds, minutes, hours, date of the DST logic subtracts the DST Adjustment time from
month, month, day of the week, and year with leap the current time when the current time is equal to
year compensation. The clock operates in 12 hour the DST End Time. To enable DST, the trim Day-
format with support for AM/PM. light Savings Time Enable needs to be set to En-
When battery power is removed or the PCC1302 abled. To setup DST, specify the values for the fol-
controller goes in sleep mode, the RTC parameters lowing trims. These trims can be set via PCTools or
get reset to 00:00 (HH:MM) for Time and 00/00/00 HMI211 or HMI211RS or via Modbus utility.

3-50
TABLE 3-26. TRIM RANGE VALUES
Trim Range Meaning
Daylight Savings End Day Monday Sunday Calendar Day in which DST Ends
Daylight Savings End Hour 01 12 hours (it is always Hour (12 Hr) in which DST Ends
AM)
Daylight Savings End Month 1 12 months Month in which DST Ends
Daylight Savings End Week Occ Default Fifth Occurrence Occurrence of Daylight Savings End Day in
Month which DST Ends
Daylight Savings End Day Monday Sunday Calendar Day in which DST Starts
Daylight Savings End Hour 01 12 hours (it is always Hour (12 Hr) in which DST Ends
AM)
Daylight Savings Start Month 1 12 months Month in which DST Starts
Daylight Savings Start Week Occ Default Fifth Occurrence Occurrence of Daylight Savings End Day in
Month which DST Starts
Daylight Savings Time Adjustmenty 0 120 minutes Amount of time to be added or subtracted
from current time for DST adjustment.

For Example: If DST Ends on the 1st Wednesday in tion is available from 1320 calibration
April at 02:00 AM every year, and DST Starts on the version 2.76 and above and HMI211
2nd Thursday in September at 3:00 AM every year, calibration version 6.90 and above.
and DST Adjusts the clock by 1 hour each time, the
parameters should be set to the following values. EXERCISE SCHEDULER
TABLE 3-27. TRIM VALUES
The exercise scheduler is a feature that automati-
Trim Value cally starts the genset for exercise. This feature
Daylight Saving End Day Wednesday prevents common problems which result from me-
chanical equipment being not in operation for long
Daylight Saving End Hour 02 periods of time. In order for the automatic exerciser
Daylight Saving End Month 4 to work, the PCC1302 control system needs to be
Daylight Saving End Week First Occurrence in Auto mode, the RTC needs to be set (Fault 1689
Occurrence in Month is not active), and the trim Scheduler Prog x Enable
needs to be set to Enable.
Daylight Saving Start Day Thursday
SLEEP mode will be disabled if the user enables
Daylight Saving Start Hour 3 the exercise scheduler. This is because sleep
Daylight Saving Start 9 mode will reset the clock (RTC) in PCC 1302 and
Month exercise function will not work.
Daylight Saving Start Second Occur- The PCC1302 can be programmed to run only 1
Week Occurrence in Month rence program, which is a repeating event. Furthermore,
Daylight Saving Time Ad- 60 the program can be programmed to exercise the
justment genset at rated condition and at No Load condi-
tion. No exceptions can be set in PCC1302.
NOTE: The software accuracy of real time The exercise program has the following trims
clock is +/ hour over a period of 1 cal- which establish its behavior where currently x al-
endar year. The real time clock func- ways denotes 1.

3-51
TABLE 3-28. TRIM SCHEDULE VALUE
Trim Value Meaning
Scheduler Prog x Enable Enable Disable Enables or Disables Schedule x=1
Scheduler Prog Start Minute 0 59 Specifies at what minute Program with start
Scheduler Prog Start Hour 1 12 Specifies at what hour Program will start
Scheduler Prog Start Day Monday Sunday Specifies at what day Program will start
Scheduler Prog Start Period AM PM Specifies at what period Program will start
Scheduler Prog Repeat Interval Weekly,Bi_Monthly,Month- Specifies the repeating behavior of Program
ly,Quarterly,SemiAnnual
Scheduler Prog Duration (Mins) 5 15 Specifies how many minutes Program will run

For example, if it was desired to have a Program Scheduler Prog Start Minute 12
that ran on every Monday at 8:12 AM for 15
Minutes, the trims should be defined in Table 328 Scheduler Prog Start Hour 8
Scheduler Prog Start Day Monday
TABLE 3-29. EXAMPLE TRIM VALUE Scheduler Prog Start Period AM
Trim Value Scheduler Prog Repeat Interval Weekly
Scheduler Prog x Enable Enable Scheduler Prog Duration (Mins) 15

3-52
TABLE 3-30. EXCERISER SCHEDULE
Scheduler Scheduler Start Time Scheduler Schedular Schedule Re-
Program Program Program Program peat Interval
Enable Start Day Duration Start Period
AM/PM
Hr Min Min Weekly Bi
monthy,
Monthly,
Quarterly
SemiAnnual
Program 1

The following are the set of rules for ATS Control


exercise scheduler Automatic Transfer Switch is used to transfer pow-
1. While in Exercise mode, genset will start if in er from Utility to Genset and viceversa. A trim
AUTO mode, and run at rated condition and at Auto Mains Failure Enable is provided to enable/
No Load disable the ATS functionality in PCC1302. There
are settable delay timers incorporated for transfer-
2. While in Exercise mode, Exercise Scheduler ring and retransferring the load from Utility to
On message will be displayed on both HMI Genset and viceversa. In addition, diagnostic
211 and HMI 211 RS. faults of ATS functionality and its corresponding
3. This message screen will be displayed for 1 FCs/ symbols are supported in HMI211 and
sec when in Info screens of the HMI and will HMI211RS.
toggle with the Info screens at a frequency of PCC 1302 has four configurable inputs, out of
3 sec. which two Configurable Inputs can be used for
checking the feedback of the switch positions i.e.
4. While in Exercise mode, the user cannot edit on Genset side or Utility side. The configurable in-
the Clock parameters, the Exercise Scheduler puts will remain locked for ATS functionality when
parameters and the Daylight Savings parame- AMF feature is enabled and the trim Transfer
ters except for the trim Scheduler Prog x En- Switch Feedback Enable is enabled.
able.
TABLE 3-31. CONFIGURABLE INPUTS
5. If the user tries to edit these trims except
Pin Signal Name
Scheduler Prog x Enable, following mes-
sage, Can Not Edit Exercise On will be dis- TB112 Configurable Input 1
played on both HMI 211 and HMI 211 RS. TB113 Configurable Input 1 Common
While in exercise scheduler mode, i.e. a scheduled TB114 Configurable Input 2
program is active and control system is in Auto
mode, if the PC1.1 control system receives a Configurable Input 1 is used for Utility switch posi-
remote start command via HMI or from PCTools or tion status and Configurable Input 2 is used for
from external transfer switch, the exercise Genset switch position status.
scheduler mode will be terminated and the For transferring the load from Utility to Genset or
Scheduler Prog Duration (Mins) timer will become viceversa, PCC1302 will use low side driver
0. However, the genset will continue to run in Auto Ready to Load/ ATS Output only.
mode and will follow ATS operation if ATS ATS functionality will only be enabled when Auto
functionality is enabled. If remote start command is Mains Failure Enable is enabled with the condition
removed then the genset will stop running. that Genset control is running in Auto mode.
NOTE: The excerise scheduler function is NOTE: When Exercise is active and if Utility
available from 1320 calibration ver- lost condition is received (remote start
sion 2.76 and above and HMI211 cal- signal is active), Genset Control dis-
ibration version 6.90 and above. cards the Exercise and continues with

3-53
the ATS functionality. The excerise above and HMI211 calibration version
scheduler function is available from 6.90 and above.
1320 calibration version 2.76 and

LOAD

SOURCE 2 SOURCE 1
GENSET UTILITY

TRANSFER SWITCH

READY TO LOAD
Ready to Load/
CONDITION GENSET UTILITY ATS Output
FEEDBACK FEEDBACK
UTILITY VOLTAGE
Config I/P 2 Config I/P 1 MONITORING
SENSOR

TB114 TB112
TB14
REMOTE START
START/STOP COMMAND
TB110
OPERATION
GENSET CONTROL

Remote HMI

FIGURE 3-30. PCC1302 BLOCK DIAGRAM

As per the block diagram shown above, do the following when Control Switch Posi-
Genset Control (PCC1302) monitors the sta- tion is in Auto.
tus of the Utility (Failing and Returning con- a. Genset Control gives the start command
dition) directly through Remote Start Com- to Genset after the Start Time delay is
mand (Active or Inactive) condition. completed.
When Utility voltage monitoring sensor b. After starting the Genset, when Genset
senses that the voltage has gone below Control reaches the Running condition,
Dropout Voltage, it will activate the Remote it starts the Transfer Delay (trim) if Auto
Start Command input. Mains Failure Enable is enabled.
When Utility voltage monitoring sensor c. When Genset Control reaches the Ready
senses that the voltage has gone above the to Load condition and Auto Mains Failure
Pickup Voltage, it will deactivate the Re- Enable is enabled and Transfer Delay is
mote Start Command input.
completed, Genset Control will activate
When Genset control receives the Remote the Ready to Load/ATS output (Customer
Start active input command, the control will Ready to load driver output) to initiate the

3-54
transfer process of the load from Utility then transferring and retransferring
source to Genset source. process depends upon Feedback
Logic and Ready to Load/ ATS Output
d. After activating the Ready to Load/ATS automatically. In Genset Control, if
output, Genset Control starts Transfer Auto Mains Failure Enable = Enabled
Delay Timer. Genset control will check for and Transfer Switch Feedback En-
Configurable Input 1 Status = Inactive able = Disabled, then transferring and
(Utility Open) and Configurable Input 2 retransferring process depends upon
Status = Active (Genset Close) feedback. Ready to Load / ATS Output status
If the feedback is not received for speci- only.
fied period of time (Transfer to Genset
Delay Timer), Genset Control will declare NOTE: The ATS control function is available
the Shutdown fault Genset Failed To from 1320 calibration version 2.76 and
Close. above and HMI211 calibration version
6.90 and above.
When Genset Control receives the Remote
Start Inactive Input Command, the Control will Dual Fuel
do the following The PCC1302 has the ability to determine the sta-
a. When Genset Control receives the Re- tus of the Fuel System and notify the user and the
mote Start Inactive Input Command and ECM.
Auto Mains Failure Enable is enabled, When Fuel Type = Gas and Engine Application
Genset Control starts ReTransfer Delay Type = FAE (ECM CAN Enable = Enabled), user
(Trim). will be able to set the trim parameter Gas Fuel Type
as Natural Gas (Default) or Propane or Dual.
b. When Genset Control receives the Re- When Gas Fuel Type is selected as Dual, the con-
mote Start Inactive Input Command and trol system has the ability to transfer the fuel source
Auto Mains Failure Enable is enabled, from Natural Gas to Propane in case a low fuel con-
Genset Control starts ReTransfer Delay dition is sensed for Natural Gas.
(Trim).
c. After deactivating the output and Auto BATTLE SHORT MODE OPTION
Mains Failure Enable is enabled, Genset
Control will check for the Configurable In- The 1302 series control can be programmed to
put 2 Status = Inactive (Genset Open) and work in battle short mode.
Configurable Input 1 Status = Active (Util- The PC service tool is required to enable the Battle
ity Close) feedback. If the feedback is not Short feature. If the operator panel is not installed,
received for specified period of time (Re the PC service tool is also required to enable the
Transfer to Utility Delay Timer), Genset external Battle Short switch.
Control will declare the Warning fault Util- The controller then can accept Configurable Input
ity Failed To Close. 1 as battle short switch inputs. If an operator panel
is used, it can be also selected as a source of input
d. Genset Control will initiate the Stop Time by selecting the appropriate input source value for
delay only when the feedback is received the trim.
otherwise Genset will continue to be in
running state. After the completion of the Installations With an Operator Panel
Stop Time delay, Genset Control will give To activate the Battle Short feature for installations
the command to stop the Genset. that include the operator panel (see Figure 3-31),
If Transfer Switch is at unknown position, Gen- 1. Use the PC service tool to enable the Battle
set Control will declare the Warning fault Short mode feature. Contact an authorized
Transfer Switch Status Unknown Position. service center for assistance.
2. View the Service Menu by simultaneously
NOTE: In Genset Control, if Auto Mains Fail-
holding down the up and down arrow keys.
ure Enable = Enabled and Transfer
Switch Feedback Enable = Enabled, 3. Select item 1, Setup Menus.

3-55
4. Enter setup menu password 574. NOTE: When Switch Input is set to Op-
erator Panel, the Battle Short:
5. Select item 1, Genset Service. Active/Inactive subject is dis-
6. Select item 1, Genset. played. Battle Short should not
be set to Active until it is needed
7. Press the selection button five times to by the customer.
view the Battleshort menu.
If you want a customer input to be the
NOTE: This menu is displayed only if the activation source of this feature, change
Battle Short mode feature has been the Switch Input: setting to Customer
enabled with the PC service tool. Input 1 or Customer Input 2. Refer to
page 5-21 for information on setting up
8. Press the ADJUST button. customer inputs.
9. Save the adjustments by pressing the Save
If you want the operator panel to be the
activation source of this feature, change button.
the Switch Input: setting to Operator For more information on the Battle Short feature,
Panel. see Section 4.

3-56
Installations Without an Operator Panel Before the Battle Short feature can be used, it must
first be enabled. Only trained and experienced ser-
Installations without a operator panel require the vice personnel should enable this feature. When
following. shipped from the factory, this feature is disabled.
A Manual Run/Off/Auto switch must be con- Installations with an Operator Panel
nected to the control harness.
Battle Short can be enabled or disabled (set to Ac-
A status indicator lamp must be installed to tive or Inactive) using the operator panel.
flash shutdown fault codes. The PC service tool is required to enable the
An external On/Off switch must be con- Battle Short mode feature. Contact an autho-
nected to one of the customer configured rized service center for assistance.
inputs on the control board. Before Battle Short can be used on installations
with the operator panel, the Switch Input setting on
The PC service tool must be used to enable the Battle Short submenu must be set to Operator
the Battle Short mode feature. Panel (see page 5-12). In addition, Battle Short
mode must be enabled (set to Active) in the Battle
The PC service tool must be used to enable
Short submenu (see page 5-12).
the external Battle Short On/Off switch.
When Battle Short mode is enabled, the Warning
Contact an authorized service center for assis-
status indicator lights, and Fault Code 1131
tance. For more information on the Battle Short
Battle Short Active is displayed.
feature, see Section 4.
When Battle Short mode is enabled and an over-
Battle Short Mode ridden shutdown fault occurs, the shutdown
lamp remains lit even though the genset continues
Battle Short mode is designed to work only in criti- to run. Fault Code 1416 Fail to Shut Down is
cal load circumstances and is used to satisfy local displayed. If the , , or button is pressed to
code requirements, where necessary. This feature acknowledge the fault, the fault message is cleared
can only be used if the necessary software was from the display but remains in the Fault History file
installed at the factory when the 1302 control was with an asterisk sign (* indicates an active fault) as
purchased or if it was installed by an authorized long as Battle Short mode is enabled.
customer service representative.
Battle Short is suspended and a shutdown occurs
Battle Short mode prevents the genset from being immediately if:
shutdown by all but a select few critical shutdown
faults. All shutdown faults, including those Any of the following shutdown faults occurs.
overridden by Battle Short, must be acted upon Overspeed Fault Code 234, Fault Code
immediately to ensure the safety and well being 1992 and Fault Code 3131
of the operator and the genset.
Emergency Stop Fault Code 1433 or
WARNING Use of the Battle Short mode fea- 1434
ture can cause a fire or electrical hazard, result-
ing in severe personal injury or death and/or Speed Signal Lost (Loss of Speed
property and equipment damage. Operation of Sense) Fault Code 121
the genset must be supervised during Battle
Short operation. Excitation Fault (Loss of Voltage
Sense) Fault Code 2335
This feature must only be used during supervised,
temporary operation of the genset. The faults that Battle Short mode is disabled after an over-
are overridden when in Battle Short mode are ridden shutdown fault occurred while in
faults that can affect genset performance or cause Battle Short mode. To disable Battle Short
permanent engine, alternator, or connected mode, navigate to the Battle Short submenu
equipment damage. Operation may void the (see page 5-12) and select Inactive. Fault
generator set warranty if damage occurs that Code 1123 Shutdown After Battle Short
relates to the fault condition(s). is then displayed.

3-57
Installations without an Operator Panel Battle Short is suspended and a shutdown occurs
immediately if:
A Manual Run/Off/Auto switch must be installed in Any of the following shutdown faults occurs.
installations that do not include a operator panel.
Battle Short can be turned on or off with a customer Overspeed Fault code 234 or 1992 or
3131
installed external switch connected to one of the
two customer configured inputs. Emergency Stop Fault code 1433 or
1434
The PC service tool is required to enable the
Battle Short mode feature and to enable the ex- Speed Signal Lost (Loss of Speed
ternal Battle Short switch using one of the two Sense) Fault code 121
available customer inputs. Contact an autho- Excitation Fault (Loss of Voltage
rized service center for assistance. Sense) Fault code 2335
When Battle Short mode is enabled and an overrid- The external Battle Short switch is moved to
den shutdown fault occurs, the genset continues to the OFF position after an active but overrid-
run and the status indicator lamp flashes the shut- den shutdown fault occurred while in Battle
down fault code. See Local Status Output on page Short mode. The status indicator lamp then
4-1 for information on interpreting the status indica- flashes Fault Code 1123 Shutdown After
tor light. Battle Short.

3-58
(2)

(7)

(3)

(7)

(4)
ENTER 574 (7)

(5)
(7)

(6)
(7)
BATTLE SHORT:
ACTIVE / INACTIVE
IS ONLY DISPLAYED
IF THE SWITCH
INPUT IS SET TO
(7) OPERATOR PANEL
(8) THIS SUBMENU IS ONLY
DISPLAYED IF THE
BATTLE SHORT FEATURE
HAS BEEN ENABLED
USING THE PC SERVICE
TOOL

NOTE: THE NUMBERS IN PARENTHESIS


MATCH THE STEPS INCLUDED IN THE
PROCEDURE LISTED ON PAGE 3-55.

FIGURE 3-31. OPERATOR PANEL MENUS FOR CALIBRATING BATTLE SHORT MODE

3-59
THIS PAGE INTENTIONALLY LEFT BLANK

3-60
4. Operator Panel Operation

LED
GRAPHICAL INDICATORS
DISPLAY

OFF MODE
BUTTON
HMI1211

DISPLAY MENU PREVIOUS MENU


SELECTION BUTTONS LEVEL BUTTON

FIGURE 4-1. 1302 OPTIONAL OPERATOR PANEL

INTRODUCTION preheat (when used) and while the generator


set is starting.
This section includes information on the following.
Local Status Output Indicator Constant On = The genset is running.
Operating Modes Intermittent Flashing = A genset shutdown
Operator Panel Description fault condition exists. All of the shutdown
Operator Panel System Messages faults described in Table 4-2 can be an-
Description of Fault and Status Codes nounced with a status indicator lamp.
Adjusting Values and Saving the Changes
For four-digit shutdown fault codes, the first
Basic Operator Menus digit in the code is flashed, followed by a half-
Selecting Auto, Manual Run, and Off Modes second pause, then the second digit is flashed,
Service Menus followed by a half-second pause, then the third
History/About Menus digit is flashed, followed by a half-second
Fault History Menu pause, and then the fourth digit is flashed, fol-
lowed by a two-second pause.
Screen Adjust Menu

LOCAL STATUS OUTPUT INDICATOR NOTE: Only the last shutdown fault is flashed.

If your installation includes a status indicator lamp When a fault is corrected, the Manual Run/Off/
that flashes genset status and shutdown fault Auto switch must be placed in the Off position
codes, the following describes how to interpret the to reset the control.
status indicator light.
Under all other indications, the status lamp is
Constant Fast Flashing = This occurs during off.

4-1
OPERATING MODES Sleep Mode
The 1302 control works with a Manual Run/Off/Auto The 1302 series control enters a low power (sleep)
switch, used to control genset operating modes. mode of operation where the current draw is not
This capability is located either in the harness greater than 60 milliamps (DC) at normal battery
(switch) or is integrated into the operator panel in- voltage levels. The control is set to enter sleep
cluded in this kit. mode after five minutes in the Off or Auto mode
(configurable).
Off Mode
Sleep mode can only be disabled by installing a
When in Off mode, the control does not allow the jumper between TB15-1 and TB15-5 (the TB15
genset to start. If the genset is already running and connector is shown in Figure 4-2).
the control is set to Off, it initiates a normal shut-
down sequence. When in Off mode, all active faults
are reset.

Manual Run Mode


When in Manual Run mode, the genset starts and
continues to run until the control is put into the Off
mode. While in Manual Run mode, any remote start
signal is ignored.

Auto Mode
When in Auto mode, the control allows the genset TB15
to be started with a remote start signal only. CONNECTOR

When in Auto mode, the genset can start at any


time. When a remote start signal is received, the
genset starts after the time delay start and time
delay preheat (if programmed) are completed.
If the genset is running in Auto mode and the Off
button is pressed, the control immediately stops
the genset and the control transitions to the Off
mode. FIGURE 4-2. TB15 CONNECTOR WITH JUMPER

When all remote start signals are removed, the The control will not enter the sleep mode if there are
control performs a normal shutdown sequence any active, unacknowledged shutdown faults, if the
which may include a time delay stop. control is in the Manual Run mode.
Emergency Stop Mode Once in sleep mode, the 1302 series control will
wake up when one of the following wakeup signals
When the optional emergency stop button is used, are received.
it immediately shuts down the generator set, by-
passing any time delay stop. The red Shutdown Local E-Stop Active when switch is open
LED lights and Fault Code 1433 or 1434 Emer- Remote E-Stop Active when switch is open
gency Stop is either displayed (installations with a
operator panel) or flashed (installations with a sta- Manual Start
tus indicator lamp). PCCNet System Wakeup
To reset the control, close (disable) the emergency Remote Start
stop button and either press the (Off) button Auto Mode (If Configured)
(installations that include a operator panel) or move
Configurable Input #3
the control switch to the OFF position (installations
with a Manual Run/Off/Auto switch). Configurable Input #4

4-2
Installations with an Operator Panel show either text or symbolic versions of fault mes-
sages, some Operator menus, and the Mode
Sleep mode is automatically enabled on the opera- Change menu. A description of commonly used
tor panel. To awaken the operator panel, press any symbols used are included in Table 4-1. Combina-
button. tions of symbols are used to display some fault con-
ditions. Additional specialized symbols are also
Installations with a Manual Run/Off/Auto
used for some faults (see Table 4-2).
Switch
TABLE 4-1. SYMBOLS
For installations that utilize an Manual Run/Off/Auto
switch located in the harness, the control awakes SYMBOL DESCRIPTION
from sleep mode if Manual Run or Auto mode (if Generator Warning Fault
configured) is selected.
OPERATOR PANEL Generator Shutdown Fault

Figure 4-1 shows the front of the optional operator Coolant Temperature
panel. It includes six LED indicators, the graphical
display, and six buttons used to navigate through Oil Pressure
the menus and adjust parameters.
Voltage Alternating Current (VAC)
Graphical Display
Voltage Direct Current (VDC)
This graphical display is used to view menus of the
menu-driven operating system. The bottom of the
graphical display indicates the functions that are AC Current
available by pressing the four selection buttons.
Refer to the menu trees later in this section. Hz Frequency

System messages (communication, event, status, Battery


and fault) are also shown on the graphical display. Out of Range
For more information, see page 4-6.
High or Pre-High
Display Text / Symbolic Versions
Low or Pre-Low
Using the Display Setup Service submenu (see
Annunciator
page 5-15), the graphical display can be set up to

4-3
Display Menu Selection Buttons When ADJUST is displayed, the selection
button is used to display an adjustable
Four momentary soft-key buttons are used to step menu. When the ADJUST button is pressed,
through the various menus and to adjust parame- the first adjustable parameter or value in the
ters. These selection buttons are active when a submenu is highlighted.
word or symbol in the graphical display is shown
When the symbol is displayed, the
above the button. Some submenus do not include
selection button is used to navigate to an
any active buttons.
editable field within a menu.
The function of the four selection buttons varies When the + and symbols are displayed,
with each menu. the selection buttons are used to increase or
decrease a parameter or value shown on the
When the symbol is displayed, the screen.
selection button can be used to switch to
Auto mode. When changing values, pressing the button
below the + symbol increase the value and
When the symbol is displayed, the selec- pressing the button below the symbol de-
tion button can be used to switch to Manual creases the value.
Run mode. When SAVE is displayed, the selection but-
ton is used to save changes made in a sub-
When the up and down triangles ( and ) menu. If the Previous Menu button is
are displayed, the selection buttons are used pressed before pressing SAVE, the
to navigate between a series of submenus. changes are not saved.
NOTE: When any Operator menu is dis- Some menus include a list of numbered sub-
played, a series of Service menus can jects. These menus include numbers in pa-
be viewed by simultaneously pressing renthesis (for example, (1)) displayed above
the and selection buttons for two the selection buttons. The selection buttons
seconds (see page 4-24). are then used to display submenus of the
subjects included in the list.
NOTE: When a fault is displayed, it can be When a black box is displayed, the
cleared from the front panel by press- selection button has no function.
ing the or button.
Previous Main Menu Button
When a symbol is displayed, the selection Press the button to view the previous main
button can be used to abort the Auto or menu.
Manual Run mode and return to the Opera-
tor menu that was displayed before the Auto NOTE: In the Screen Adjust menu, settings are not
or Manual Run mode was selected. saved when the button is pressed.

4-4
possible, this hot shutdown should be avoided to
help prolong the reliability of the genset.
Not In Auto Indicator
This red lamp is lit when the control is not in the
Auto mode.
Shutdown Indicator
This red lamp is lit when the control detects a Shut-
down condition. The generator set cannot be
started when this lamp is on. After the condition is
OFF corrected, the lamp can be reset by performing a
BUTTON
fault reset. When Battle Short mode is enabled and
an overridden shutdown fault occurs, the Shut-
down lamp is lit even though the genset continues
to run.
Warning Indicator
This yellow lamp is lit whenever the control detects
PREVIOUS MAIN a warning condition. This lamp is automatically
MENU BUTTON shut off when the warning condition no longer ex-
ists.
Remote Start Indicator
This green lamp indicates the control is receiving a
remote start signal.
Auto Indicator
FIGURE 4-3. PREVIOUS MAIN MENU AND OFF
BUTTONS This green lamp indicates the control is in Auto
mode. Auto mode can be selected by pressing the
Off Button selection button from any of the Operator me-
nus (see page 4-22).
Press the button to switch to the Off mode. The
Off mode disables the control Auto or Manual Run Manual Run Indicator
modes.
This green lamp indicates the control is in the
If the button is pressed during genset operation Manual Run mode. Manual Run mode can be se-
(manual or remote start), the engine immediately lected by pressing the selection button from any
shuts down and the control enters the Off mode. If of the Operator menus (see page 4-22).

4-5
OPERATOR PANEL SYSTEM MESSAGES If either communication message remains dis-
played (cannot view other menus), this is an in-
A system pop-up message is displayed when the dication that communications between the op-
event it is displaying becomes active. These pop- erator panel and the control logic is lost. Con-
up messages remain displayed until pre-empted by tact an authorized service center for service.
another pop-up message or until the or the
display buttons is pressed or the event has expired. Event Messages
Once the or the button is pressed, the pre- When pre-set events (start or stop) are activated,
vious screen is redisplayed. Event messages are displayed showing the time
remaining until the event occurs (see Figure 4-6).
Communication Messages
System messages are displayed for initial power-
up or when there is a subsequent loss of commu-
Event = START,
nications. Auto and Manual Run modes can also be or STOP
selected when communication messages are dis-
played (for more information, see page 4-22).
Upon initial power-up, the message Establishing
communication with control is displayed (see Fig-
ure 4-4). This menu also displays the screens soft-
ware number and version. FIGURE 4-6. EVENT MESSAGE

Status Messages
Status messages for some events are displayed on
the optional control panel with a code number but
are not announced with a lamp indicator. Text sta-
tus messages include the event code, a short de-
scription, and the time the event occurred. Symbol-
ic status messages include the event code and
symbols to indicate the type of event that occurred.
FIGURE 4-4. ESTABLISHING COMMUNICATIONS
MESSAGE

When the display detects that it is no longer com-


municating with the control, the Shutdown, Warn-
ing, and Remote Start LEDs are turned off.
If communications are lost, the message Re-es-
tablishing communication with control is displayed
until communications have been re-established
(see Figure 4-5). The LEDs then return to the state
determined by the control. FIGURE 4-7. DATASAVE STATUS MESSAGE

On Full Authority Electronic engines, the engine


controller saves data after each run. During this
time, the display displays the message shown in
Figure 4-7. The generator can still be started while
the ECM Datasave is in progress.
Fault Messages
A Fault message is an indicator of a Warning or
FIGURE 4-5. RE-ESTABLISHING Shutdown condition that is also announced with a
COMMUNICATIONS MESSAGE lamp indicator. Text fault messages include the

4-6
fault code number, a short description, and when Fault Reset / Acknowledgement
the fault occurred (see Figure 4-8). Symbolic fault
messages include the fault code number and sym-
bols, indicating the type of fault (see Figure 4-9). Shutdown faults must be acknowledged after the
With the symbolic versions of fault messages, the fault condition has been corrected. Shutdown
and symbols flash. faults are usually acknowledged by one of the fol-
lowing methods.
Five of the most recent faults are saved in a file and
can be viewed using the Fault History Menus (see
page 4-28). If the control is equipped with an operator
panel, press the button.

If the control is not equipped with and opera-


Fault = WARNING tor panel, place the Auto/Off/Manual Run
or SHUTDOWN
switch in the Off position.

Shutdown faults can also be acknowledged when


in Auto mode by using an external customer-sup-
plied remote fault reset switch. This ability must be
enabled by setting the Remote Fault Reset En-
FIGURE 4-8. FAULT MESSAGE TEXT VERSION
abled trim to Enabled (disabled by default) using
InPower.

EXAMPLE OF The remote fault reset switch must be wired into


A SYMBOLIC one of the four configurable inputs. The chosen
WARNING
FAULT
214 configurable input should have its function mapped
to the Fault Reset function. To reset the fault, the
remote start command must be removed prior to
the remote fault reset switch being activated.

Faults are removed from the display when they are


EXAMPLE OF cleared.
A SYMBOLIC
SHUTDOWN 1
FAULT
NOTE: Pressing the or button also clears the
fault from the front panel display.

FIGURE 4-9. FAULT MESSAGES SYMBOLIC Faults are re-announced if they are detected again
VERSION after being acknowledged.

4-7
FAULT/STATUS CODES Category C Fault Codes: Consist of faults that do
not affect generator set performance but require
Table 4-2 provides a list of fault and status codes, qualified service personnel to repair. These codes
types, displayed messages/symbols, descriptions, indicate a defective harness or wiring problem.
and fault categories (CTG). These codes can also indicate a defective engine
sensor, leaving no ingine protection. (Engine dam-
Category A Fault Codes: Pertain to engine or al- age can occure without detection.) Continued op-
ternator shutdown faults that require immediate re- eration may void the generator set warranty if
pair by trained and experienced service personnel damage occures that relates to the fault condi-
(generator set non-operational). The control pre- tion.
vents the generator set from being restarted if a
shutdown fault is not corrected. Category D Fault Codes: Consist of faults that are
repairable by site personnel. Service will be re-
Category B Fault Codes: Consist of faults that quired by trained and experienced service person-
can affect generator set performance or can cause nel if site personnel cannot resolve the problem.
engine, alternator, or connected equipment
damage. Operate the genset only when it is power- Category E Fault Codes: Indicates non-critical
ing critical loads and cannot be shut down. Catego- operational status of generator set, external faults,
ry B faults require repair by trained and experi- or customer fault inputs. These faults require repair
enced service personnel. by trained and experienced service personnel.

TABLE 4-2. FAULT AND STATUS CODES


DISPLAYED MESSAGE/SYMBOLS
CTG CODE LAMP SYMBOLIC DESCRIPTION
TEXT VERSION
VERSION
A 121 Shutdown SPEED SIGNAL Indicates that no magnetic pickup pulses
LOST were sensed for a Loss of Speed delay. If
121 a magnetic pickup is disabled, this fault is
not activated.
C 135 Warning OIL PRESS Indicates the oil pressure sensor output is
SENSOR OOR
HIGH
135 out of range (OOR), high.

C 141 Warning OIL PRESS Indicates the oil pressure sensor output is
SENSOR OOR
LOW
141 out of range (OOR), low.

B 143 ** Warning PRE-LOW OIL Indicates that the engine oil pressure is
PRESSURE 143 approaching an unacceptable level.
C 144 Warning COOLANT Indicates the coolant temperature sensor
SENSOR OOR
LOW 144 output is out of range (OOR), low.

C 145 Warning COOLANT Indicates the coolant temperature sensor


SENSOR OOR
HIGH 145 output is out of range (OOR), high.

C 146 ** Warning PRE-HIGH Indicates that the engine has begun to


COOLANT TEMP
146 overheat and the engine coolant tempera-
ture has risen to an unacceptable level.
NOTE: Shutdown fault codes can also be announced with a local status lamp indicator.
* For more information on these events, refer to the Battle Short Mode description on page 3-57.
** Any values listed in the Description column for these faults are default values. If authorized, these values
can be changed using the Genset Setup menus (see page 5-37).
^ These faults are available only if your installation includes the optional I/O Module (Kit 5411291).

4-8
TABLE 4-2. FAULT AND STATUS CODES (CONT.)
DISPLAYED MESSAGE/SYMBOLS
CTG CODE LAMP SYMBOLIC DESCRIPTION
TEXT VERSION
VERSION
D 151 ** Shutdown HIGH COOLANT Indicates that the engine coolant tempera-
TEMP
151 ture is above normal and has reached the
shutdown trip point.
C 153 Warning INTAKE Indicates the intake manifold temperature
MANIFOLD sensor is out of range (OOR), high.
TEMP OOR 153
HIGH
C 154 Warning INTAKE Indicates the intake manifold temperature
MANIFOLD
TEMP OOR LOW
154 sensor is out of range (OOR), low.

D 155 Shutdown INTAKE Indicates that the intake manifold


MANIFOLD
TEMP HIGH
155 temperature is above normal and has
reached the shutdown trip point.
D 195 Warning COOLANT Indicates that a sensor on the radiator has
LEVEL OOR
HIGH
195 detected that the coolant level is out of
range (OOR), high.
D 196 Warning COOLANT Indicates that a sensor on the radiator has
LEVEL OOR
LOW
196 detected that the coolant level is out of
range (OOR), low.
D 197 Warning COOLANT Indicates that a sensor on the radiator has
LEVEL LOW
197 detected that the coolant level is below
normal.
A 234 ** Shutdown OVERSPEED Indicates that the engine has exceeded
normal operating speed. The default
234 thresholds are 1725 RPM (50 Hz) or 2075
RPM (60 Hz).
A 285 Shutdown ECM PGN Datalink failure. PCC control not
TIMEOUT 285 responding to the engine control module.

A 286 Shutdown ECM Indicates an engine control module


CONFIGURABLE
ERROR
286 configuration error out of calibration.

D 359 Shutdown FAIL TO START The genset has failed to start after a set

359 number of crank attempts. This indicates a


possible fuel system problem (engine
cranks but fails to start).
A 415 Shutdown LOW OIL Indicates the engine oil pressure has
PRESSURE
415 dropped below normal and has reached
the shutdown trip point.
C 421^ Shutdown OIL TEMP HIGH Indicates that the engine oil temperature is
421 above normal and has reached the
shutdown trip point. (I/O Module option)
NOTE: Shutdown fault codes can also be announced with a local status lamp indicator.
* For more information on these events, refer to the Battle Short Mode description on page 3-57.
** Any values listed in the Description column for these faults are default values. If authorized, these values
can be changed using the Genset Setup menus (see page 5-37).
^ These faults are available only if your installation includes the optional I/O Module (Kit 5411291).

4-9
TABLE 4-2. FAULT AND STATUS CODES (CONT.)
DISPLAYED MESSAGE/SYMBOLS
CTG CODE LAMP SYMBOLIC DESCRIPTION
TEXT VERSION
VERSION
418 NONE N/A N/A Indicates water in fuel
B 425^ Shutdown OIL TEMP OOR Indicates the oil temperature sensor output
425 is out of range (OOR), high or low. (I/O
Module option)
A 426 Shutdown DATA LINK Datalink failure. No communications
ERROR
426 between the PCC control and the engine
control module.
A 427 Warning CAN LINK LOST Datalink fault. Indicates that important data
427 was lost between the PCC control and the
engine control module.
D 441 ** Warning LOW BATTERY Indicates battery voltage supply to the con-
441 trol is approaching a low level at which un-
predictable operation can occur.
D 442 ** Warning HIGH BATTERY Indicates battery voltage supply to the con-
442 trol is approaching a high level at which
damage to the control can occur.
D 488^ Shutdown INTAKE Indicates the intake manifold temperature
MANIFOLD
TEMP HIGH
488 is above normal and has reached the
shutdown trip point. (I/O Module option)
A 689 Shutdown ENGINE SPEED Indicates a fault condition in the engine
ERRATIC 689 crankshaft sensor circuit.

A 781 Shutdown CAN LINK LOST Datalink failure. No communications


781 between the PCC control and the engine
control module.
D 1117 Warning ECM POWER Indicates battery voltage supply to the
LOST 1117 engine control module was lost.

B 1123 Shutdown SHUTDOWN A shutdown fault occurred while the Battle


* AFTER BS 1123 Short mode was enabled.

D 1131 Warning BATTLE SHORT Indicates that the control is in Battle Short
* ACTIVE mode used to bypass several fault shut-
1131 downs for genset operation during emer-
gencies.
C 1246 Warning GENERIC Engine control fault code not recognized
ENGINE FAULT 1246 by the PCC control.

E 1311 Configur- Customer Fault The nature of the fault is an optional cus-
able Input 1 1311 tomer selection.

E 1312 Configur- Customer Fault The nature of the fault is an optional cus-
able Input 2 1312 tomer selection.

NOTE: Shutdown fault codes can also be announced with a local status lamp indicator.
* For more information on these events, refer to the Battle Short Mode description on page 3-57.
** Any values listed in the Description column for these faults are default values. If authorized, these values
can be changed using the Genset Setup menus (see page 5-37).
^ These faults are available only if your installation includes the optional I/O Module (Kit 5411291).

4-10
TABLE 4-2. FAULT AND STATUS CODES (CONT.)
DISPLAYED MESSAGE/SYMBOLS
CTG CODE LAMP SYMBOLIC DESCRIPTION
TEXT VERSION
VERSION
E 1317 Configur- Customer Fault The nature of the fault is an optional cus-
able Input 3 1317 tomer selection.

E 1318 Configur- Customer Fault The nature of the fault is an optional cus-
able Input 4 1318 tomer selection.

B 1416 Warning FAIL TO Indicates that a shutdown fault is active,


* SHUTDOWN 1416 but is being bypassed by Battle Short.

A 1417 Shutdown FAILURE TO Indicates the control is powered up after


POWER DOWN 1417 attempting to go to sleep.

D 1433 Shutdown LOCAL Indicates a Local Emergency Stop has


EMERGENCY
STOP
1433 been activated.

D 1434 Shutdown REMOTE Indicates a Remote Emergency Stop has


EMERGENCY
STOP
1434 been activated.

D 1435 Warning LOW COOLANT Indicates that the engine coolant tempera-
** TEMP ture is below the adjusted setpoint. This
1435 may indicate that the coolant heater is not
operating or is not circulating coolant.
D 1438 Shutdown FAIL TO CRANK The genset has failed to sense rotation for
1438 two start attempts. This indicates a pos-
sible fault with the control, speed sensing,
or the starting system.
D 1442 Warning WEAK BATTERY Indicates that the genset battery voltage is
** 1442 below battery thresholds during cranking.
A 1443 Shutdown DEAD BATTERY Indicates during cranking battery voltage
has dropped below operating voltage of
1443 control resetting the control for three con-
secutive times.
A 1446 Shutdown HIGH AC Indicates that the one or more measured
** VOLTAGE AC output voltages has exceeded the
threshold for longer than a specified time
1446 limit. The threshold and time limits are
130% of nominal for 0 seconds or 110% of
nominal for 10 seconds.
A 1447 Shutdown LOW AC Indicates that the measured AC output
** VOLTAGE voltage is below the threshold for longer
1447 than a specified time limit. The threshold
and time limits are 85% of nominal for 10
seconds.
NOTE: Shutdown fault codes can also be announced with a local status lamp indicator.
* For more information on these events, refer to the Battle Short Mode description on page 3-57.
** Any values listed in the Description column for these faults are default values. If authorized, these values
can be changed using the Genset Setup menus (see page 5-37).
^ These faults are available only if your installation includes the optional I/O Module (Kit 5411291).

4-11
TABLE 4-2. FAULT AND STATUS CODES (CONT.)
DISPLAYED MESSAGE/SYMBOLS
CTG CODE LAMP SYMBOLIC DESCRIPTION
TEXT VERSION
VERSION
A 1448 Shutdown UNDER Indicates that the alternator frequency is 6
** FREQUENCY Hz 1448 hertz under nominal frequency.
A 1449 Shutdown OVER Indicates that the alternator frequency is 6
** FREQUENCY Hz 1449 hertz above nominal frequency.
1463 NONE N /A N/A Indicates Not in Auto.
1468 NONE N/A N/A Indicates Ready to Load.
A 1469 Shutdown SPEED HZ Indicates that measured engine speed and
** MATCH measured alternator AC output frequency
do not agree.
B 1471* Warning HIGH AC Indicates that the alternator output current
* CURRENT
1471 (one or more phases) has exceeded safe
operating limits.
A 1472 Shutdown HIGH AC Indicates that alternator output current
** CURRENT
1472 (one or more phases) has exceeded the
alternators current rating.
1483 NONE N/ A N/A Indicates Common Alarm.
1540 NONE N/ A N/A Indicates Common Warning.
1541 NONE N/ A N/A Indicates Common Shutdown.
C 1845 Warning WATER IN FUEL Indicates the water in fuel sensor is out of
OOR HIGH 1845 range (OOR), high.

C 1846 Warning WATER IN FUEL Indicates the water in fuel sensor is out of
OOR LOW 1846 range (OOR), low.

D 1852 Warning WATER IN FUEL Indicates that the water in fuel is above
1852 normal and has reached the warning trip
point.
E 1853 Configur- Annunciator Fault The nature of the annunciator fault is an
able 2 1853 optional customer selection.
E 1854 Configur- Annunciator Fault The nature of the annunciator fault is an
able 3 1854 optional customer selection.
E 1855 Configur- Annunciator Fault The nature of the annunciator fault is an
able 1 1855 optional customer selection.
E 1944 Warning ANNUNCIATOR Indicates a mismatch in the configuration
OUTPUT CON- of one of the annunciator relay outputs.
FIGURATION 1944
ERROR
D 1965 Warning EXHAUST Indicates the exhaust temperature sensor
^ TEMPERATURE
OOR
1965 is out of range (OOR), high or low. (Aux
101 I/O option).
NOTE: Shutdown fault codes can also be announced with a local status lamp indicator.
* For more information on these events, refer to the Battle Short Mode description on page 3-57.
** Any values listed in the Description column for these faults are default values. If authorized, these values
can be changed using the Genset Setup menus (see page 5-37).
^ These faults are available only if your installation includes the optional I/O Module (Kit 5411291).

4-12
TABLE 4-2. FAULT AND STATUS CODES (CONT.)
DISPLAYED MESSAGE/SYMBOLS
CTG CODE LAMP SYMBOLIC DESCRIPTION
TEXT VERSION
VERSION
B 1992 Warning ENGINE Indicates that the engine has exceeded
OVERSPEED normal operating speed. The default
1992 thresholds are 1725 RPM (50 Hz) or 2075
RPM (60 Hz). (ECM fault code).
B 1689 Warning CLOCK NOT Indicates real time clock is not set with
SET 1689 exercise scheduler function enabled.

B 5186 Warning GENSET FAILED Indicates transfer switch has failed to close
TO CLOSE 5186 on generator side.

B 5187 Warning UTILITY FAILED Indicates transfer switch has failed to close
TO CLOSE 5187 on utility side.

B 5188 Warning TRANSFER Indicates transfer switch position is not


SWITCH known.
STATUS
UNKNOW
5188
POSITION
B 5365 Warning ON Indicates genset is running on secondary
SECONDARY
SOURCE
5365 fuel source in dual fuel application.

B 2118 Warning LOW FUEL Indicates low fuel pressure sensed for
PRESSURE 2118 gaseous application.

B 5134 Warning UNKNOWN Indicates genset having ECM has


SHUTDOWN AT
IIDLE
5134 shutdown with unknown fault before
reaching rated condition.
B 254 Warning FSO DRIVER Engine Fuel Shutoff Valve Driver Circuit
FAILED 254 Voltage Below Normal or Shorted.

B 1847 Warning HIGH Indicates that engine coolant temperature


TEMPERATURE
FAULT
1847 is above normal and has reached the
shutdown trip point.
B 1517 Warning FAILED At least One Module of a Multimodule
MODULE
SHUTDOWN
1517 system has a severe fault.

B 1921 Warning REGEN Aftertreatment Diesel Particulate Filter


MANDATORY Differential Pressure Data Valid But
HIGH LEVEL
1921 Above Normal Operating Range
Moderately Severe Level. Need to initiate
DPFprocess.
NOTE: Shutdown fault codes can also be announced with a local status lamp indicator.
* For more information on these events, refer to the Battle Short Mode description on page 3-57.
** Any values listed in the Description column for these faults are default values. If authorized, these values
can be changed using the Genset Setup menus (see page 5-37).
^ These faults are available only if your installation includes the optional I/O Module (Kit 5411291).

4-13
TABLE 4-2. FAULT AND STATUS CODES (CONT.)
DISPLAYED MESSAGE/SYMBOLS
CTG CODE LAMP SYMBOLIC DESCRIPTION
TEXT VERSION
VERSION
B 1922 Warning GENSET Aftertreatment Diesel Particulate Filter
CRITICAL CALL Differential Pressure Data Valid But
TECHNICIAN
1922 Above Normal Operating Range Most
Severe Level. Need to call Cummins
technician to clear the fault.
B 175 Warning AIR THROT Electronic Throttle Control Actuator Driver
DRIVE CCT
OORH
175 Circuit Voltage Above Normal or Shorted
to High Source.
B 176 Warning AIR THROT Electronic Throttle Control Actuator Driver
DRIVE CCT
OORH
176 Circuit Voltage Below Normal or Shorted
to Low Source.
B 177 Warning AIR THROT Electronic Throttle Control Actuator
DRIVE MECH
SYS ERROR
177 Mechanical System Not Responding or
Out of Adjustment.
B 3539 Warning AIR THROT Engine Intake Throttle Actuator Position
POSN SENSOR
OORH
3539 Sensor Circuit Voltage Above Normal or
Shorted to High Source.
B 3541 Warning AIR THROT Engine Intake Throttle Actuator Position
DRIVE CCT
OORL
3541 Sensor Circuit Voltage Below Normal or
Shorted to Low Source.
B 3542 Warning AIR THROT Engine Intake Throttle Actuator Position
POSN SENS
DATA INCORR
3542 Sensor Data Erratic, Intermittent, or
Incorrect.
B 5669 Warning ENGINE Intake Manifold Over Pressure Condition
COMBUSTION
FAULT
5669 Exists.

C 2224 Warning FUEL LEVEL Indicates the fuel level sensor is out of
^ OOR
2224 range (OOR), high or low. (Aux 101 I/O
option).
A 2335 Shutdown EXCITATION Indicates that a loss of voltage or frequen-
FAULT
2335 cy sensing from the generator has oc-
curred.
C 2398 Warning AMBIENT Indicates the ambient temperature sensor
^ TEMPERATURE
OOR
2398 is out of range (OOR), high or low. (Aux
101 I/O option).
C 2542 Warning VOLTAGE BIAS Indicates the voltage bias circuit output is
^ OOR
2542 out of range (OOR), high or low. (Aux 101
I/O option).
A 2545 Shutdown KEYSWITCH Indicates a datalink failure. Communica-
RESET
REQUIRED
2545 tions are lost between the PCC control and
the engine control module.
NOTE: Shutdown fault codes can also be announced with a local status lamp indicator.
* For more information on these events, refer to the Battle Short Mode description on page 3-57.
** Any values listed in the Description column for these faults are default values. If authorized, these values
can be changed using the Genset Setup menus (see page 5-37).
^ These faults are available only if your installation includes the optional I/O Module (Kit 5411291).

4-14
TABLE 4-2. FAULT AND STATUS CODES (CONT.)
DISPLAYED MESSAGE/SYMBOLS
CTG CODE LAMP SYMBOLIC DESCRIPTION
TEXT VERSION
VERSION
E 2619 Diagnos- AUX101 ANA- The nature of the Base I/O Module event
^ tic LOG INPUT 1 is an optional customer selection. (Aux101
I/O Module option)
Each event function can be programmed
2619 (using InPower service tool or access to
the Setup menu), as follows:
Change display name using up to 32
characters.
Select active low or high input.
E 2621 Diagnos- AUX101 ANA- See code 2619.
^ tic LOG INPUT 2 2621
E 2622 Diagnos- AUX101 ANA- See code 2619.
^ tic LOG INPUT 3 2622
E 2623 Diagnos- AUX101 ANA- See code 2619.
^ tic LOG INPUT 4 2623
E 2624 Diagnos- AUX101 ANA- See code 2619.
^ tic LOG INPUT 5 2624
E 2625 Diagnos- AUX101 ANA- See code 2619.
^ tic LOG INPUT 6 2625
E 2626 Diagnos- AUX101 ANA- See code 2619.
^ tic LOG INPUT7 2626
E 2627 Diagnos- AUX101 ANA- See code 2619.
^ tic LOG INPUT 8 2627
E 2628 Diagnos- AUX102 DIGITAL The nature of the Aux I/O Module event is
^ tic INPUT 9 an optional customer selection. (Aux102
I/O Module option)
Each event function can be programmed
2628 (using InPower service tool or access to
the Setup menu), as follows:
Change display name using up to 32
characters.
Select active low or high input.
E 2629 Diagnos- AUX102 DIGITAL See code 2628.
^ tic INPUT 10 2629
E 2631 Diagnos- AUX102 DIGITAL See code 2628.
^ tic INPUT 11 2631
NOTE: Shutdown fault codes can also be announced with a local status lamp indicator.
* For more information on these events, refer to the Battle Short Mode description on page 3-57.
** Any values listed in the Description column for these faults are default values. If authorized, these values
can be changed using the Genset Setup menus (see page 5-37).
^ These faults are available only if your installation includes the optional I/O Module (Kit 5411291).

4-15
TABLE 4-2. FAULT AND STATUS CODES (CONT.)
DISPLAYED MESSAGE/SYMBOLS
CTG CODE LAMP SYMBOLIC DESCRIPTION
TEXT VERSION
VERSION
E 2632 Diagnos- AUX102 DIGITAL See code 2628.
^ tic INPUT 12 2632
A 2676 Shutdown ALTERNATOR Indicates the measured alternator line fre-
FREQUENCY quency and measured alternator excitation
CONFLICT frequency do not agree.
A 2677 Shutdown FAIL TO STOP The genset continues to run after receiving
2677 a stop command from the controller.
B 2678 Warning CHARGER Indicates the battery charging alternator
** FAILURE has not reached a acceptable voltage
range within the selected time period (de-
fault = 120 seconds).
This warning is also displayed if your alter-
2678 nator is a type that does not support the
controls charging alternator logic function-
ality. If this occurs, this warning can be dis-
abled if the Charging Alt. Enable setting is
set to No. See the Genset Service sub-
menus on page 5-8.
C 2693 Warning SPEED BIAS Indicates the speed bias circuit output is
^ OOR
2693 out of range (OOR), high or low. (Aux 101
I/O Module option).
C 2694 Warning ALTERNATOR Indicates the alternator RTD sensor is out
^ RTD OOR
2694 of range (OOR), high or low. (Aux 101 I/O
Module option).
A 2696 Shutdown ALTERNATOR Indicates the alternator temperature is
^ RTD TEMP HIGH
2696 above normal and has reached the
shutdown trip point. (I/O Module option)
C 2729 Warning I/O MODULE Indicates an intermittent data link between
^ LOST
2729 the I/O module and the PCC control. (Aux
101 I/O Module option).
C 2731 Shutdown I/O MODULE Indicates the data link between the I/O
LOST
2731 module and the PCC control is lost. (Aux
101 I/O Module option).
A 2897 Shutdown FACTORY Indicates a fatal software error occurred in
BLOCK
CORRUPT
2897 the PCC control.

A 2898 Warning PERIODIC/ Indicates a fatal software error occurred in


FAULT
CORRUPT
2898 the PCC control.

A 2899 Shutdown USER BLOCK Indicates a fatal software error occurred in


CORRUPT 2899 the PCC control.

NOTE: Shutdown fault codes can also be announced with a local status lamp indicator.
* For more information on these events, refer to the Battle Short Mode description on page 3-57.
** Any values listed in the Description column for these faults are default values. If authorized, these values
can be changed using the Genset Setup menus (see page 5-37).
^ These faults are available only if your installation includes the optional I/O Module (Kit 5411291).

4-16
TABLE 4-2. FAULT AND STATUS CODES (CONT.)
DISPLAYED MESSAGE/SYMBOLS
CTG CODE LAMP SYMBOLIC DESCRIPTION
TEXT VERSION
VERSION
A 2911 Shutdown TRIM BLOCK Indicates a fatal software error occurred in
CORRUPT 2911 the PCC control.

D 2964 Warning INTAKE Indicates engine has begun to overheat


MANIFOLD (intake manifold temperature has risen to
TEMPERATURE an unacceptable level). Increase in load or
HIGH 2964 higher ambient temperature may cause
Intake Manifold Temp High (code 155)
shutdown.
A 2972 Shutdown FIELD Indicates that the Field Voltage has been
** OVERLOAD 2972 above 70V for 8 seconds.

NOTE: Shutdown fault codes can also be announced with a local status lamp indicator.
* For more information on these events, refer to the Battle Short Mode description on page 3-57.
** Any values listed in the Description column for these faults are default values. If authorized, these values
can be changed using the Genset Setup menus (see page 5-37).
^ These faults are available only if your installation includes the optional I/O Module (Kit 5411291).

ADJUSTING DEFAULT SETTINGS When the SAVE button is pressed, the previous
menu is redisplayed.
The optional operator panel can be set up to dis-
play with SAE or SI units of measurement. OPERATOR MENUS
Figures 4-10 and 4-11 show block representations
For more information, see the Adjust Screen menu of the following Operator menus.
shown on page 4-30.
Engine Status
SAVING YOUR CHANGES Alternator Status
Line-to-Line Voltage
All adjustments made to menus are temporary until
Line-to-Neutral Voltage
the SAVE button is pressed. If the SAVE button is
pressed and the engine is running, the adjustments Alternator Amperage
are not saved until after the engine speed is zero. If To navigate between the Operator menus, press
power is lost to the control before a SAVE is execut- the buttons next to the and symbols in the
ed, all temporary adjustments are lost. graphical display.
Adjustments to the following are stored in flash The Operator menus can be used to select Auto or
memory in the optional operator panel. Manual Run modes (see page 4-22).
Engine Status Menu
Contrast
This menu displays the engine starting battery volt-
Brightness
age, engine coolant temperature, engine oil pres-
Units sure, and hours of engine operation.
Local or remote display Alternator Status Menu
Symbols or text displayed This menu displays genset load (in kVA), frequen-
Access code required for mode change to cy, and engine speed (RPM).
Auto or Manual Run Alternator Line-to-Line Voltage Menu
All other adjustments are stored in the control This menu displays L1-L2, L2-L3, and L3-L1 line-
board. to-line voltages for three phase applications only.

4-17
Alternator Line-to-Neutral Voltage Menu ages for single phase applications only.
This menu displays line-to-neutral voltages for L1,
L2, and L3 for three phase wye configurations only. Alternator Amperage Menu
In delta configurations, this menu is not shown.
Alternator Single Phase Voltage Menu For applications that include current transformers,
this menu displays L1, L2, and L3 current sense
This menu displays L1-N, L2-N, and L1-L2 volt- amperage.

4-18
OPERATOR MENUS Text Version

THREE PHASE
ONLY SINGLE
PHASE
ONLY

THREE PHASE
WYE ONLY

CURRENT SENSE
AMPERAGE

FIGURE 4-10. OPERATOR MENUS (TEXT VERSION)

4-19
OPERATOR MENUS Symbolic Version

THREE PHASE
SINGLE
ONLY
PHASE
ONLY

THREE PHASE
WYE ONLY

CURRENT SENSE
AMPERAGE

FIGURE 4-11. OPERATOR MENUS (SYMBOLIC VERSION)

4-20
SELECTING AUTO, MANUAL RUN, AND 2. Press the arrow selection button to move
OFF MODES to the next numeric character.

Auto, Manual Run, and Off modes can be selected: 3. Press the button below the + or symbols until
the value reads 2.
From any of the Operator menus
4. Press the arrow selection button to move
When the message Establishing commu- to the next numeric character.
nication with control is displayed
5. Press the button below the + or symbols until
When the message Re-establishing com- the value reads 1.
munication with control is displayed
6. After you have completed entering the pass-
Switching to Auto, Manual Run, or Off mode can be word, press the arrow selection button .
restricted to authorized personnel. If a operator
panel is set up with the mode change access code NOTE: If an incorrect password is entered,
feature enabled, an access code must first be en- the Operator menu that was displayed
tered before the mode can be changed. The mode before Auto, Manual Run, or Off mode
change access code feature is enabled through the was selected is redisplayed.
Display Setup submenu (see page 5-15).
The Auto or Off mode switch status is saved in non-
volatile memory when it changes. When the control
panel powers up (after sleeping or upon battery re-
moval), the switch status is restored to its previous TEXT VERSION
saved state.

Entering the Mode Change Access Code


If the mode change feature access code is en-
abled, an access code must be entered to switch to
Auto, Manual Run, or Off modes. The text and sym-
bolic versions of the Mode Change menu are SYMBOLIC VERSION
shown in Figure 4-12.
To enter the mode change access code,

1. With the first character highlighted, press the


button below to the + or symbols until the val-
ue reads 1. FIGURE 4-12. MODE CHANGE MENU

4-21
Selecting Auto Mode
To switch to Auto mode (see Figure 4-13),

1. Press the button on any of the Operator


menus or the Establishing/Re-establishing
communication with control menus.

2. If the mode change access code feature is en-


abled, the Mode Change Access Code menu
is displayed. Enter the mode change access THIS MENU IS
code as described above. DISPLAYED ONLY IF
THE MODE CHANGE
3. A menu with alternating arrows is displayed ACCESS CODE
FEATURE IS ENABLED
above a second symbol. Press the sec-
ond button. The Operator menu that was
displayed before Auto mode was selected is
redisplayed.

To disable Auto mode, press the button.


NOTE: Manual Run mode can also be selected ALTERNATING
ARROWS ARE
while in Auto mode. DISPLAYED

AUTO MODE
SELECTED

FIGURE 4-13. SELECTING AUTO MODE

4-22
Selecting Manual Run Mode

To switch to Manual Run mode (see Figure 4-14),

To switch to Manual Run mode,

1. Press the button on any of the Operator me-


nus or the Establishing/Re-establishing com-
munication with control menus.
THIS MENU IS
2. If the mode change access code feature is en- DISPLAYED ONLY IF
THE MODE CHANGE
abled, the Mode Change Access Code menu ACCESS CODE
is displayed. Enter the mode change access FEATURE IS ENABLED
code as described on the previous page.

3. A menu with alternating arrows is displayed


above a second symbol. Press the second
button. The Operator menu that was dis-
played before Manual Run mode was selected ALTERNATING
is redisplayed. ARROWS ARE
DISPLAYED

To disable Manual Run mode, press the button.

NOTE: Auto mode can also be selected while in


Manual Run mode. Switching to Auto mode
may result in the generator set shutting
down.

Aborting the Transition to Auto or Manual MANUAL


RUN MODE
Run Mode SELECTED

If the Mode Change Access Code menu or the


menu showing alternating arrows above the
or buttons is displayed, the transition to Auto or
Manual Run mode is aborted when:
FIGURE 4-14. SELECTING MANUAL RUN MODE
Either the , , or button is pressed.

A selection button is not pressed within ten Selecting Off Mode


seconds.
To switch to Off mode, press the button. If the
If the transition to Auto or Manual Run mode is genset is running and Off mode is selected, a nor-
aborted, the Operator menu that was displayed be- mal shutdown sequence is initiated. More informa-
fore Auto or Manual Run mode was selected is re- tion on the use of the Off button is included on page
displayed 4-5.

4-23
SERVICE MENUS The third Service Menu can be viewed by pressing
the selection button on the second Service
Figure 4-15 shows a block representation of the Menu. The third Service Menu provides access to
menus available from the Service Menus. the Network Status menus.
The first Service Menu can be viewed from any of
the Operator menus by simultaneously pressing Status Menu
the and selection buttons for two seconds.
The first Service Menu provides access to the fol- The Status menu is displayed when the (5) button
lowing menus: is pressed on the second Service Menu. The Sta-
tus menu shows the following:
Setup Menus Used by Service personnel.
Adjusting the Setup menus is restricted by a Voltage regulator (drive) level, in percentage
password and is described in the Control of duty cycle.
Service section. To view the Setup menus
only, press the VIEW button on the Setup Governor regulator (drive) level, in percent-
password menu. age of duty cycle. This value is only dis-
History / About see page 4-26 played if the governor is enabled.

Screen Adjust see page 4-30 Network Status Menus


To return to the Operator menu that was displayed
The Network Status menus are displayed when the
prior to viewing the Service Menu, press the
(7) button is pressed on the third Service Menu.
button.
Two menu are used to display the quantity of the
The second Service Menu can be viewed by press- following devices that are connected to the net-
ing the selection button on the first Service work.
Menu. The second Service Menu provides access Universal Annunciators
to the following menus:
Bar graphs
Fault History see page 4-28
Battery chargers
Status see below
Controls
Lamp Test The six LEDs on the control
I/O modules
panel should light as long as the button (6) is
pressed. Operator panels (any type)

4-24
1ST
SERVICE
MENU

SETUP MENUS HISTORY / ABOUT MENUS SCREEN ADJUST MENU


SEE PAGE 5-4 SEE PAGE 4-26 SEE PAGE 4-30

2ND 3RD
SERVICE SERVICE
MENU MENU

FAULT HISTORY MENUS


SEE PAGE 4-28

FIGURE 4-15. SERVICE MENUS

4-25
HISTORY / ABOUT MENUS About Genset Submenus
Figure 4-16 shows a block representation of the Two submenus display the generator set model
History / About menus. The first History / About number, control number, and genset application
submenu is displayed when the (2) button is frequency rating.
pressed on the Service Menu (see Figure 4-15).
About Control Submenu
Press the buttons next to the and symbols in
the graphical display to navigate between the His- This submenu displays the controls part number,
tory / About submenus. Press the button to re- serial number (up to 11 characters), software part
turn to the Service Menu. number (up to 9 characters), and software version.

History Submenu About Display Submenu


This submenu displays the number of engine This submenu displays the optional control panel
starts, hours of operation for the engine, and hours software part number, software version, screen
of operation for the control. part number, and screen version of the display.

4-26
HISTORY / ABOUT MENUS

FIGURE 4-16. HISTORY / ABOUT MENUS

4-27
FAULT HISTORY MENU Information on faults is included in Table 4-2 on
page 4-8.
Figure 4-18 shows a block representation of the
Fault History menu. The first Fault menu is dis-
played when the (4) button is pressed on the sec- TIME FAULT
ond Service Menu (see Figure 4-15). If there are OCCURRED
any active fault submenus, an Active Fault head- FAULT
ing is displayed for the most recent active fault. All CODE
other fault submenus display a Fault History
heading. Five of the most recent faults can be
viewed. An example of how a fault code is dis- FAULT
played is shown in Figure 4-17. DESCRIPTION

Press the buttons next to the and symbols in


the graphical display to navigate between menus.

Press the button to return to the Service Menu. FIGURE 4-17. FAULT HISTORY MENU EXAMPLE

4-28
FAULT HISTORY MENU

Active Fault Fault 1

OR

Fault 2

Oldest Fault
(Maximum of 5)

FIGURE 4-18. FAULT HISTORY MENU

4-29
SCREEN ADJUST MENU NOTE: If the Previous Menu button is
pressed before pressing the SAVE
Figure 4-19 shows a block representation of the button, the changes are not saved.
Screen Adjust menu. The Screen Adjust menu is
displayed when the (3) button is pressed in the first 5. Press the button to return to the Service
Service Menu (see Figure 4-15). Menu.
Screen Adjust Menu
Adjusting Values/Parameters
This menu allows for adjusting the screens con-
1. Press the ADJUST selection button to select trast and brightness and for selecting the units of
the first parameter or value to be changed. measurement (SAE or SI) to be displayed.
2. Press the + or selection buttons to adjust val- Contrast and Brightness: Press the + or
ues or select parameters. selection buttons to adjust the screens con-
trast and brightness. Changing the bright-
3. Press the arrow selection button to navi- ness setting also affects the brightness of
gate to the next or previous adjustable value or the LEDs on the operator panel.
parameter.
Units: Press the + or selection buttons to
4. After adjusting values/selecting parameters, select SAE (_F, PSI) or SI (C, kPa) units of
press the SAVE button to save your settings. measurement to be displayed.

SCREEN ADJUST MENU

FIGURE 4-19. SCREEN ADJUST MENU

4-30
5. 1302 Control Panel Service Menus
SERVICE MENUS To return to the Operator menu that was displayed
prior to viewing the Service Menu, press the
NOTE: When using any PCCNet device on a gen- button.
set control application, the wiring used to
connected ALL devices in the network The second Service Menu can be viewed by press-
must be Belden 9729 Two Pair, Stranded, ing the selection button on the first Service
Shielded Twisted Pair Cable (24 AWG). Menu. The second Service Menu provides access
to the following menus:
CAUTION Incorrect settings can result in
equipment malfunction and damage. Only Fault History
trained and experienced personnel should be
authorized to change the settings. Status
The Service Menus shown in this section can be
viewed and, if the correct password(s) are entered, Lamp Test The six LEDs on the control
modified. Changing the settings should be re- panel should light as long as the button (6) is
stricted to trained and experienced installation and pressed.
service personnel.
The third Service Menu can be viewed by pressing
Figure 5-1 shows a block representation of the me- the selection button on the second Service
nus available from the Service Menu. Menu. The third Service Menu provides access to
the Network Status menus. The Network Status
The first Service Menu can be viewed from any of menus are displayed when the (7) button is
the Operator menus by simultaneously pressing pressed on the third Service Menu. Two menu are
the and selection buttons for two seconds. used to display the quantity of the following devices
The first Service Menu provides access to the fol- that are connected to the network.
lowing menus:
Universal Annunciators
Setup Menus See page 5-3
Bar graphs
History / About See page 4-27
Battery chargers
Screen Adjust See page 4-30
Controls
Changes can be made to Adjust submenus without
I/O modules
entering a password. However, a password is re-
quired to change any of the Setup submenus. Operator panels

5-1
1ST
SERVICE
MENU

SETUP MENUS HISTORY / ABOUT MENUS SCREEN ADJUST MENU


SEE PAGE 5-4 SEE PAGE 4-26 SEE PAGE 4-30

2ND 3RD
SERVICE SERVICE
MENU MENU

FAULT HISTORY MENUS STATUS MENU


SEE PAGE 4-28 SEE PAGE 4-24

NETWORK STATUS MENUS


SEE PAGE 4-24

FIGURE 5-1. SERVICE MENUS

5-2
SETUP MENUS
The Setup menus are available by pressing the (1)
button on the first Service menu (see Figure 5-1).
The Setup Menus (see Figure 5-2) provide access
to genset menus with settings that can be viewed
and, if a password is entered, adjusted.
The first Setup menu is displayed when the (1) but-
ton is pressed on the Service Menu. From the Set-
up Password menu, a second Setup menu is dis-
played that provides access to the following two
categories of genset menus.
Genset Service menus
Genset Setup menus Go to page 5-35

FIGURE 5-2. SETUP MENUS

5-3
GENSET SERVICE MENUS The Genset Service menus can be viewed by se-
lecting the VIEW button on the Setup Password
The first Genset Service menu is available by menu and then selecting (1) on the second Setup
pressing the (1) button on the Setup Menus menu menu. When the VIEW button is selected without
(see Figure 5-2). entering the correct password, the ADJUST button
This section covers Genset Service menus only. is not displayed on any of the Genset Service me-
For information on Genset Setup menus, go to nus; therefore, no adjustments can be made.
page 5-35.
Menu Navigation
If a password is entered, the settings in the Genset
Service menus can be adjusted. However, if a
password is not entered, these menus can still be 1. Press the buttons above the and sym-
viewed. bols in the digital display to navigate between
submenus.
Viewing Only
Figure 5-3 is a block representation of the Genset 2. To return to the genset Setup Menus menu
Service menus that are available when a password from any of the submenus, press the but-
is not entered (or an incorrect password is entered) ton.
in the Setup Password menu.
The first Genset Service Menu provides access to 3. To return to the Service Menu from the genset
the following menus: Setup Menus menu, press the button.
Genset
Customer I/O
Meter Calibration
The second Genset Service Menu provides access
to the following menus:
Annunciator
ModBus

5-4
GENSET SERVICE MENUS (Viewing Only)
NOTE: When the VIEW button is selected
from the Setup Password menu with-
out entering a password, the AD-
JUST button is not available on any of
the menus shown in Figures 5-5 thru
5-14.

1ST VIEW
GENSET
SERVICE
MENU

2ND VIEW
GENSET
SERVICE
MENU

SEE PAGE 5-21

SEE PAGE 5-8 SEE PAGE 5-27 SEE PAGE 5-29 SEE PAGE 5-34

FIGURE 5-3. VIEWING GENSET SERVICE MENUS WITHOUT ENTERING A PASSWORD

5-5
Viewing and Adjusting 2. Press the arrow selection button to move
to the next numeric character.
Figure 5-4 is a block representation of the Genset
3. Press the button below the + or symbols until
Service menus that are available from the Setup
the value reads 7.
Menus menu after the correct password has been
entered. The ADJUST button is available on these 4. Press the arrow selection button to move
submenus; therefore, adjusting the settings is al- to the next numeric character.
lowed. 5. Press the button below the + or symbols until
The first Genset Service Menu provides access to the value reads 4.
the following menus: 6. After you have completed entering the pass-
word, press the arrow selection button .
Genset The first main Setup menu is displayed.
Customer I/O After the correct password is entered, it will be re-
Meter Calibration membered until five minutes of button inactivity has
elapsed. If five minutes of button inactivity has
The second Genset Service Menu provides access elapsed, you will have to re-enter the password to
to the following menus: access and change Setup menus.

Annunciator Adjusting Values/Parameters


ModBus Once the correct password has been entered and
Genset Service (1) is selected on the Setup Menus
Setup Password Submenu menu, the first Genset Service submenu is dis-
played.
Adjusting the Genset Service menus is restricted to
service personnel and a password must be entered 1. Press the buttons above the and sym-
to modify these menus. bols in the digital display to navigate between
submenus.
When the Password menu is displayed, the first nu-
meric character (0) is highlighted (see Figure 5-4). 2. Press the ADJUST selection button to select
the first parameter or value to be changed.
NOTE: When selected (highlighted), each charac-
ter initially turns to 0 and the remaining 3. Press the + or selection buttons to adjust val-
characters turn to X. ues or select parameters.

NOTE: Make sure that each numeric character is 4. Press the arrow selection button to navi-
correct before you move to the next char- gate to the next or previous adjustable value
acter. If a wrong character is entered, you or parameter.
will not be able to go back and correct it. If 5. After adjusting values/selecting parameters,
the wrong password is entered, you will be press the SAVE button to save your settings.
able to view the Genset Service menus but
you wont be able to change them. NOTE: If the button is pressed before
pressing the SAVE button, the
To enter the password: changes are not saved.
1. With the first character highlighted, press the
button below to the + or symbols until the val- 6. Press the button to return to the Service
ue reads 5. Menu.

5-6
GENSET SERVICE MENUS (Viewing and Adjusting)

1ST
GENSET
SERVICE
MENU

2ND
GENSET
SERVICE
MENU

SEE PAGE 5-21

SEE PAGE 5-8 SEE PAGE 5-27 SEE PAGE 5-29 SEE PAGE 5-34

FIGURE 5-4. GENSET SERVICE MENUS

5-7
Genset Service Submenus The average engine speed (if a mag-
netic pickup unit is installed)
The Genset Service submenus are available by The average frequency
pressing the (1) button on the first Genset Service
menu (see Figure 5-3 or Figure 5-4). The charging alternator voltage (if the
Charging Alt feature is enabled)
The Genset Service submenus consist of ten basic
submenus. The Charging Alt. Enable menu is used to en-
able or disable the Charging Alt feature. While
Genset, Part 1 the default setting is Yes, this menu provides
Genset, Part 2 a means to disable the controls charging alter-
nator logic if it is not supported by your alterna-
Fuel System tor. If your alternator does not support this
Start/Stop Time Delays functionality, the Charger Failure warning
(fault code 2678) will constantly be displayed
Cycle Crank
unless this setting is changed to No. When
Battle Short (if enabled) disabled (set to No), the start disconnect sig-
Automatic Voltage Regulator Setup* nal is based only on the average engine speed
or frequency and the Charger Failure warning
Electronic Governor* is disabled.
Genset Model and Serial Number
Fuel System
Display Setup
The Fuel System menu allows for selecting fuel
Volts and Hz Password type and, depending on the type selected, enab-
* If enabled, the Automatic Voltage Regulator has ling/disabling glow plugs or setting a fuel burn time
two additional submenus and the Electronic Gov- delay.
ernor has five additional submenus. Fuel System: Allows for selecting the fuel
Genset Menu, Part 1 type (Diesel or Gas, default = Diesel).
If Fuel System is set to Diesel
The first genset menu displays the preset AC Volt-
age, genset frequency, number of phases, and Glow Plug Enable: Allows control of Glow
phase type. Plugs for a particular genset (Yes or No, de-
fault = No).
Volts AC: Displays the AC voltage (190, 200,
208, 220, 230, 240, 380, 400, 416, 440, 460, If Fuel System is set to Gas
480, or 600 VAC, default = 208). Fuel Burn Delay: After the genset receives a
Hertz: Displays the genset frequency (50 or stop signal, this feature allows for setting a
60 Hz, default = 60 Hz). The control selects fuel time delay from 0 to 10 seconds (default
limits, gains, and frequency values based = 5 seconds) in which the ignition remains
upon this selection. on so that any fuel down stream of the in-
take manifold is burned.
No. of Phases: Displays the number of
phases (1 or 3, default = 3). Start/Stop Delay Menu
Phase: Displays the phase type (Delta or The time delay after receiving a valid start signal,
Wye default = Wye). until the genset starts, can be adjusted. The time
delay that the genset is allowed to ruin at rated
Genset Menu, Part 2
speed after receiving a stop signal, until the genset
The second genset menu allows for enabling or stops, can also be adjusted. These time delays do
disabling charging alternators. not apply to manual start/runs.

Charging Alt. Enable: Start: The genset start time delay can be ad-
justed from 0 to 300 seconds (default = 0
A starter disconnect will occur whenever any seconds) or 0 to 3600 seconds from 1320
one of the following three possible signals calibration version 2.80, HMI211 calibration
reaches its disconnect setpoint. version 7.20 onwards.

5-8
Stop: The genset stop time delay can be
adjusted from 0 to 600 seconds (default = 0
seconds).

5-9
GENSET SERVICE SUBMENUS

WHEN FUEL SYSTEM IS


SET TO DIESEL, THE
GLOW PLUG ENABLE B
SUBJECT IS DISPLAYED.
WHEN FUEL SYSTEM IS
SET TO GAS, THE FUEL
BURN DELAY SUBJECT
IS DISPLAYED.

A
CONTINUED ON
PAGE 5-12

FIGURE 5-5. GENSET SERVICE SUBMENUS (SHEET 1 OF 4)

5-10
Cycle Crank Menu (see page 3-57 for more Battle Short information).
Before the Battle Short feature can be used, one of
The Cycle Crank menu allows for configuring the three available activation sources must be se-
generator for all starting modes (manual and re- lected. If the activation source switch input is set to
mote), as follows: Operator Panel, then Battle Short functionality
can be enabled or disabled with this menu.
Crank: The cranking period can be set from
3 to 30 seconds (default = 15 seconds). This Switch Input: The Switch Input can be set for
time limit is used to determine a Fail to Start Configurable Input 1, Configurable Input 2,
status. Operator Panel, or None (default = None).
Rest: The minimum amount of time between Battle Short: Battle Short functionality can be
crank attempts can be set from 0 to 60 sec- enabled or disabled (set to Active or Inac-
onds (default = 30 seconds). tive), (default = Inactive). This subject will
only be displayed if the switch input is set to
Attempts: The maximum number of times Operator Panel.
the starter can be engaged when attempting
to start the engine with cycle cranking can AVR Setup Menu
be set from 1 to 7 attempts (default = 3).
The AVR Setup menu is used to enable or disable
Battle Short Menu the automatic voltage regulator (default = Yes). If
enabled, two additional menus are displayed that
This menu is displayed only if the PC service tool can be used to adjust the AVR settings (see page
has been used to enable the Battle Short feature 5-18).

5-11
GENSET SERVICE SUBMENUS (Continued)
RETURN TO
A
PAGE 5-10
B

THIS SUBMENU IS ONLY


DISPLAYED IF THE BATTLE
SHORT FEATURE HAS BEEN
ENABLED USING THE PC
SERVICE TOOL
BATTLE SHORT: ACTIVE /
INACTIVE IS ONLY DISPLAYED
IF THE SWITCH INPUT IS SET
TO OPERATOR PANEL

YES NO
K
OR

C E
GO TO AVR CONTINUED
SETUP MENUS ON PAGE 5-14
ON PAGE 5-18

FIGURE 5-5. GENSET SERVICE SUBMENUS (SHEET 2 OF 4)

5-12
Electronic Governor Menu, Part 1 Electronic Governor Menu, Part 2
The Pre-Load Offset menu is used to enter a per-
The engine Electronic Governor Enable menu is centage of governor duty cycle that is first used
used to enable or disable the electronic governor when exiting cranking.
on gensets with electronic governors and magnetic
Genset Number Menu
pickup sensors (default = Yes). If enabled (set to
Yes), four additional menus are displayed that The Genset Number menu is used to enter the gen-
can be used to adjust governor settings (see page sets model and serial numbers. Each allow up to
5-20). 16 characters to be entered.

5-13
GENSET SERVICE SUBMENUS (Continued)
RETURN TO
E
PAGE 5-12
F

IF AVR IS NOT
ENABLED
OR

YES NO IF AVR IS
ENABLED
OR
H
GO TO
PAGE 5-18
D
GO TO
GOVERNOR
SETUP MENUS
ON PAGE 5-20

L
CONTINUED
ON PAGE 5-16

FIGURE 5-5. GENSET SERVICE SUBMENUS (SHEET 3 OF 4)

5-14
Display Setup Menu Manual Run, or Off) change access code
(default = No).
The Display Setup menu is used to set the display
for Local (Auto/Off/Manual Run switch functions Symbols: A display can be set up to display
on the operator panel are turned on) or Remote international symbols on the Operator me-
(Auto/Off/Manual Run switch functions on the op- nus (default = Yes).
erator panel are turned off).
Volts and Hertz Menu
Connection: A display can be set up to be
Local or Remote (default = Local). The Volts and Hertz menu is used to select whether
or not a password is required in order to change
Access Code: A display can be set up to re- voltage and hertz settings outside of the Genset
quire or not require entering the mode (Auto, Service menus (default = Required).

5-15
GENSET SERVICE SUBMENUS (Continued)

RETURN TO
PAGE 5-14
L M

FIGURE 5-5. GENSET SERVICE SUBMENUS (SHEET 4 OF 4)

5-16
Automatic Voltage Regulator Submenus NOMINAL
VOLTAGE

The Automatic Voltage Regulator (AVR) subme- KNEE FREQUENCY


nus are available only if the AVR is enabled (see NOMINAL
(100%)
page 5-12). VOLTAGE SET-
SLOPE
VOLTAGE POINT CURVE

Two Automatic Voltage Regulator (AVR) subme- FREQUENCY


nus (see Figure 5-7) can be used to adjust Volts/Hz
Rolloff and Regulator Gains settings. NOMINAL
FREQUENCY

Volts/Hz Rolloff Menu FIGURE 5-6. KNEE FREQUENCY AND SLOPE

V/Hz Knee: The Knee Frequency can be ad-


The Volts/Hz Rolloff function helps optimize the justed from 0.0 to 10.0 Hertz in 0.1 Hz incre-
gensets response to added load. If the engine ments (default = 1.0 Hz). When generator set
speed drops below nominal frequency, the control speed decreases by more than the value of
automatically drops the voltage until the engine the knee frequency, the generator set voltage
speed starts to recover. decreases by the %/Hz value.
V/Hz Rolloff: The Rolloff setting can be ad-
This menu allows for adjusting the knee frequency justed from 0.0 to 5.0 percent of rated volt-
and voltage setpoint slope parameters. The knee age, in 0.1% increments (default = 2.0%).
frequency is the value below nominal frequency at
which the rolloff function begins. For example, if the Regulator Gains Menu
knee frequency is set to 5 Hz on a 60 Hz genset, The Regulator menu allows for setting proportional
this function begins when the frequency drops be- Gain, Integral Gain, and Damping values.
low 55 Hz.
Gain: The proportional Gain (K1) multiplier
Slope refers to how fast the voltage is rolled off be- can be set from 5 to 1000% (default =
low the knee frequency. The voltage is rolled off the 100%). This allows for a scale factor of 0.05
slope percent setting for every 1 Hz below the to 10.0.
knee. For example, on a 60 Hz genset, if the slope
Int: The Integral Gain (K2) multiplier can be
is set to 5% and the knee frequency is set to 5 Hz,
set from 5 to 1000% (default = 100%).
then if the frequency drops to 54 Hz, the voltage set
point is reduced 5%. If the frequency drops to 53 D: The Damping adjustment can be set from
Hz, the voltage set point is reduced 10%, etc. 95 to 105% (default = 100%).

5-17
AUTOMATIC VOLTAGE REGULATOR SUBMENUS

NOTE: These menus are only available if RETURN TO


the Automatic Voltage Regulator PAGE 5-12
(AVR) is enabled (see page 5-12). C F

RETURN TO
PAGE 5-12

FIGURE 5-7. AUTOMATIC VOLTAGE REGULATOR SUBMENUS

5-18
Electronic Governor Submenus Int: The integral governor gain (K2) multiplier
can be set from 5 to 1000% (default =
The Electronic Governor submenus are available 100%).
only if the governor is enabled (see page 5-12).
D: The governor Damping adjustment can
Four Electronic Governor submenus (see Figure be set from 95 to 105% (default = 100%).
5-8) can be used to adjust governor settings.
Governor Crank Fuel Menu Electronic Governor Menu

The Governor Crank Fuel menu allows for setting The Electronic Governor menu allows for setting
the Initial Crank Fuel Duty Cycle, the Initial Crank Crank Exit Fuel DC, Dither Factor, and Damping
Fueling Period, the Crank Fuel Ramp Rate, and the values. This menu is displayed only if the governor
Maximum Crank Fuel Duty Cycle. has been enabled with the Engine Electronic Gov-
ernor Enable menu.
Initial DC: The Initial Crank Fuel Duty Cycle
is the initial value assigned to the Governor Crank Exit Fuel DC: The Crank Exit Fuel
Duty Cycle parameter when cranking be- Duty Cycle is the value at which the gover-
gins. This value can be set from 0 to 50 per- nor duty cycle is held after disengaging the
cent (default = 25%). starter until the governor is enabled. This
value can be set from 0 to 100% (default =
Initial Time: The Initial Crank Fueling Period 25%).
is the amount of time for which the value of
Initial Crank Fuel Duty Cycle is assigned to Dither Factor: Dither is a signal that is super-
the governor duty cycle after cranking be- imposed on the PWM (pulse with modula-
gins. This value can be set from 0 to 10 sec- tion) duty cycle to prevent the actuator valve
onds (default = 2 seconds). from sticking. The Dither Factor is the dither
percent added to the current duty cycle. The
Ramp Rate: The Crank Fuel Ramp Rate is
Dither Factor can be set from 0 to 30% (de-
the rate at which the value of the Governor
fault = 15%). The dither function is disabled
Duty Cycle is ramped up by during the
when the dither factor is set to 0%.
Crank State, after expiration of the Initial
Crank Fueling Period. This value can be set Ramp Time: This feature is used to set the
from 5 to 100 (default = 25). minimum governor speed reference ramp
Max DC: The Maximum Crank Fuel Duty rate. The governor Ramp Time can be set
Cycle is the maximum level to which the from 0.00 to 30.0 seconds, in 0.01 second
Governor Duty Cycle should be limited to increments (default = 0.25 seconds).
during a crank state. This value can be set
from 50 to 100% (default = 100%). Electronic Governor Enable Speed Menu

Electronic Governor Regulator Menu These menus allow for setting the minimum and
maximum governor duty cycle.
The Electronic Governor Regulator menu allows
for setting proportional Gain, Integral Gain, and Min. Gov DC: The Minimum Governor Duty
Damping values. Cycle can be set from 0 to 100% (default =
5%).
Gain: The proportional governor gain (K1)
multiplier can be set from 5 to 1000% (de- Max. Gov DC: The Maximum Governor Duty
fault = 100%). This allows for a scale factor Cycle (with dithered value) can be set from 0
of 0.05 to 10.0. to 100% (default = 95%).

5-19
ELECTRONIC GOVERNOR SUBMENUS
NOTE: These menus are only available D RETURN TO
PAGE 5-14
if the governor is enabled (see
page 5-12). G

RETURN TO
PAGE 5-14

FIGURE 5-8. ELECTRONIC GOVERNOR SUBMENUS

5-20
Customer I/O Submenus Short (the default is different for each input). See
Figure 5-9.
The Customer I/O menus are available by pressing
the (2) button on the first Genset Service menu Customer Inputs
(see Figure 5-3 or Figure 5-4). The Customer Input Text message menus are
used to enter an event type and description for up
The Customer I/O menus (see Figures 5-9 thru
to four events. See Figure 5-10.
5-12) can be used to define customer input mes-
sages and output maps. The Customer I/O menus Type: Enter the event type (Warning, Shut-
consist of four Fault Input Function Selection me- down or Event, default = Warning).
nus, four Customer Input Test message menus,
four Fault Input Active State Selection menus, and Enter a brief description of the event (up to
two Customer Output Map menus. 32 characters).
Fault Input Active State Selection
Fault Input Function Selection
Each of the four fault input active states can be set
Each of the four configurable input functions can be to Active Closed or Active Open, (default = Active
set to Disabled, Fault Input, Fault Reset or Battle Open). See Figure 5-11.

5-21
FAULT INPUT FUNCTION SELECTION SUBMENUS

GO TO
CUSTOMER
INPUT MENUS
ON PAGE 5-23

FIGURE 5-9. CUSTOMER I/O SUBMENUS (SHEET 1 OF 4)

5-22
CUSTOMER INPUT SUBMENUS
A B RETURN TO
PAGE 5-22

GO TO FAULT
INPUT ACTIVE
STATE MENUS ON
PAGE 5-24

FIGURE 5-10. CUSTOMER I/O SUBMENUS (SHEET 2 OF 4)

5-23
FAULT INPUT ACTIVE STATE SELECTION SUBMENUS
C D RETURN TO
PAGE 5-23

GO TO
CUSTOMER
OUTPUT MENUS
ON PAGE 5-26

FIGURE 5-11. CUSTOMER I/O SUBMENUS (SHEET 3 OF 4)

5-24
Customer Outputs able customer outputs. See Figure 5-12.
Number: Enter a valid code number
Two Customer Outputs are configurable to display (065535, default = 0) for the event.
common warning alarms. The two Customer Out-
put Map menus allow for entering a fault number A brief description of the event is automati-
and fault name to be displayed for the two configur- cally displayed.

5-25
CUSTOMER OUTPUT SUBMENUS

RETURN TO
PAGE 5-24
E F

FIGURE 5-12. CUSTOMER I/O SUBMENUS (SHEET 4 OF 4)

5-26
Metering Submenus Freq. Adjust Menu

The Metering submenus are available by pressing The Frequency Adjust menu allows for adjusting
the (3) button on the first Genset Service menu the genset frequency. The frequency can be adjust
(see Figure 5-3 or Figure 5-4). from 6.0 to +6.0 Hz (default = 0.0 Hz). The actual
frequency is also shown on this menu.
Three Metering submenus (see Figure 5-13) can
be used to adjust regulated voltage, frequency, Metering Voltage Adjust Menu
line-to-neutral voltage, and line current settings.
The Metering Voltage Adjust menu allows for ad-
Meter Calib Menu justing metered line voltage.
The Meter Calib menu allows for adjusting the ac- Metering Current Adjust Menu
tual output voltage of the genset. The percentage
can be set from 90 to 110% (default = 100%). The The Metering Current Adjust menu allows for ad-
alternator voltage is also shown on this menu. justing metered amps.

5-27
METERING SUBMENUS

FIGURE 5-13. METERING SUBMENUS

5-28
Annunciator Submenus Annunciator Inputs
The annunciator has three possible customer-de-
The Annunciator submenus are available by press-
fined fault conditions that can be shown on the
ing the (4) button on the second Genset Service
1302 series control display. The Annunciator Fault
menu (see Figure 5-3 or Figure 5-4).
Text message menus are used to enter an event
Seven annunciator submenus (see Figure 5-14) type and description for those three customer-de-
can be used to define three Annunciator Fault Text fined annunciator faults.
messages and four Annunciator Output Maps. Type: Enter the event type (Warning, Shut-
down, or Event, default = Warning).
Enter a brief description of the event (up to
32 characters).

5-29
ANNUNCIATOR SUBMENUS

CONTINUED ON
PAGE 5-32

FIGURE 5-14. ANNUNCIATOR SUBMENUS (SHEET 1 OF 2)

5-30
Annunciator Outputs NOTE: Output relays can be configured for events
that are not displayed by the operator pan-
An annunciator has four custom (N.O.) relays that
el. If one of the events listed in the following
can be controlled by the PCC 1302. When a speci-
fied event becomes active, a message can be sent table is configured, it will activate the relay
by the PCC 1302 to the annunciator to turn the when the event occurs.
relay on or off. Only one event per relay is allowed.
The four annunciator outputs of the 1302 series
control are configurable to display common warn- TABLE 5-1. EVENT AND CODES
ing alarms. The four Annunciator Output Map me- EVENT CODE
nus allow for entering a fault number and fault Water In Fuel 418
name to be displayed for the configurable annun-
ciator outputs. Not In Auto 1463
Ready to Load 1468
Number: Enter a valid code number
(065535, default = 0) for the event. Common Alarm 1483
Common Warning 1540
A brief description of the event is automati-
cally displayed. Common Shutdown 1541

5-31
ANNUNCIATOR SUBMENUS (Continued)
RETURN TO PAGE 5-30
A B

FIGURE 5-14. ANNUNCIATOR SUBMENUS (SHEET 2 OF 2)

5-32
ModBus Submenus ModBus Setup
The ModBus Setup menu is used to set the ad-
The ModBus submenus are available by pressing
dress, baud rate, and parity.
the (5) button on the second Genset Service menu
(see Figure 5-3 or Figure 5-4). Address: Enter the address of the control on
the ModBus register (default = 1).
ModBus Enable
Baud Rate: Enter the appropriate baud rate
2400, 4800, 9600, or 19200 (default =
The ModBus menu is used to enable or disable the 9600).
ModBus feature (default = No).
Parity: The parity can be set to either odd or
even (default = even).

5-33
MODBUS SUBMENUS

FIGURE 5-15. MODBUS SUBMENUS

5-34
GENSET SETUP SUBMENUS Viewing Only

The first Setup menu is displayed when the (1) but- Figure 5-17 is a block representation of the Genset
ton is pressed on the Service Menu. From the Set- Setup menus that are available when a password
up Password menu, a Setup Menus menu is dis- is not entered (or an incorrect password is entered)
played that provides access to the following two in the Genset Setup Password menu.
categories of genset menus. The first Genset Setup Menu provides access to
the following menus:
Genset Service menus Go to page 5-3
Genset
Genset Setup menus
Voltage Protection
This section covers Genset Setup menus only. A
password does not need to be entered on the Set- Current Protection
up Password menu in order to view or adjust the The second Genset Setup Menu provides access
Genset Setup submenus. to the following menu:
When the (2) button is selected to access Genset Engine Protection
Setup menus, a second password menu (Genset
The Genset Setup submenus can be viewed by se-
Setup Password) is displayed (see Figure 5-16). If
lecting the VIEW button on the Genset Setup Pass-
a password is entered on the Genset Setup Pass-
word menu. When the VIEW button is selected
word, the settings in the Genset Setup menus can
without entering the correct password, the AD-
be adjusted. However, if a password is not entered,
JUST button is not displayed on any of the Genset
these menus can still be viewed.
Setup menus; therefore, no adjustments can be
made.
Menu Navigation
SETUP 1. Press the buttons above the and sym-
PASSWORD bols in the digital display to navigate between
MENU
submenus.

2. To return to the genset Setup Menus menu


from any of the submenus, press the but-
ton.

3. To return to the Service Menu from the genset


SETUP Setup Menus menu, press the button.
MENUS
MENU

GENSET SETUP
PASSWORD
MENU

FIGURE 5-16. SETUP PASSWORD MENUS

5-35
GENSET SETUP MENUS (Viewing Only)
NOTE: When the VIEW button is selected from
the Genset Setup Password menu with-
out entering a password, the ADJUST
button is not available on any of the me-
nus shown in Figures 5-19 thru 5-22.

1ST
GENSET
SETUP
MENU

AVAILABLE ONLY IF THE ECM


CAN FEATURE IS DISABLED

2ND
GENSET
SETUP
MENU

SEE PAGE 5-46

SEE PAGE 5-40 SEE PAGE 5-48 SEE PAGE 5-50

FIGURE 5-17. GENSET SETUP MENUS (VIEWING ONLY)

5-36
Viewing and Adjusting 3. Press the button below the + or symbols until
the value reads 2.
Figure 5-18 is a block representation of the Genset
4. Press the arrow selection button to move
Setup menus that are available after the correct
to the next numeric character.
password has been entered in the Genset Setup
Password menu. The ADJUST button is available 5. Press the button below the + or symbols until
on these submenus; therefore, adjusting the set- the value reads 0.
tings is allowed.
6. Press the arrow selection button to move
The first Genset Setup Menu provides access to to the next numeric character.
the following menus: 7. Press the button below the + or symbols until
the value reads 9.
Genset
8. After you have completed entering the pass-
Voltage Protection word, press the arrow selection button .
The first main Setup menu is displayed.
Current Protection
After the correct password is entered, it will be re-
The second Genset Setup Menu provides access membered until five minutes of button inactivity has
to the following menu: elapsed. If five minutes of button inactivity has
Engine Protection elapsed, you will have to re-enter the password to
access and change Genset Setup menus.
Genset Setup Password Submenu
Adjusting Values/Parameters
Adjusting the Genset Setup menus is restricted to
Once the correct password has been entered on
service personnel and a password must be entered
the Genset Setup Password menu, the first Genset
to modify these menus.
Setup submenu is displayed.
Once the Genset Setup button (2) is selected on
1. Press the buttons above the and sym-
the Setup Menus menu, the Genset Setup Pass-
bols in the digital display to navigate between
word menu is displayed.
submenus.
When the Genset Setup Password menu is dis-
played, the first numeric character (0) is highlighted 2. Press the ADJUST selection button to select
(see Figure 5-18). the first parameter or value to be changed.

NOTE: When selected (highlighted), each charac- 3. Press the + or selection buttons to adjust val-
ter initially turns to 0 and the remaining ues or select parameters.
characters turn to X.
4. Press the arrow selection button to navi-
NOTE: Make sure that each numeric character is gate to the next or previous adjustable value
correct before you move to the next char- or parameter.
acter. If a wrong character is entered, you
5. After adjusting values/selecting parameters,
will not be able to go back and correct it. If
press the SAVE button to save your settings.
the wrong password is entered, you will be
able to view the Genset Setup menus but
you wont be able to change them. NOTE: If the button is pressed before
pressing the SAVE button, the
To enter the password: changes are not saved.

1. With the first character highlighted, press the 6. Press the button to return to the genset
button below to the + or symbols until the val- Setup Menus menu.
ue reads 1.
2. Press the arrow selection button to move 7. To return to the Service Menu from the genset
to the next numeric character. Setup Menus menu, press the button.

5-37
GENSET SETUP MENUS (Viewing and Adjusting)

1ST
GENSET
SETUP
MENU

AVAILABLE ONLY IF THE ECM


CAN FEATURE IS DISABLED

2ND
GENSET
SETUP
MENU

SEE PAGE 5-46

SEE PAGE 5-40 SEE PAGE 5-48 SEE PAGE 5-50

FIGURE 5-18. GENSET SETUP MENUS (VIEWING AND ADJUSTING)

5-38
Genset Menus Excitation/Line Freq. Gain: If the excitation
source is set to Shunt, this value is auto-
The Genset submenus are available by pressing matically set to 1. If the excitation source is
the (1) button on the first Genset Setup menu (see set to PMG, the value that should be en-
Figure 5-17 or Figure 5-18). tered is the excitation frequency multiplier of
the PMG system. For example, enter a 2 if
Genset Menu 1 the PMG output is twice the main generator
The first Genset Setup menu is used to set the CT frequency (120 Hz excitation frequency).
Ratio, enable the Magnetic Pickup Unit (MPU), set Application Rating Select Menu
the number of teeth pulses per revolution on the
Flywheel, and set the Speed/Frequency Ratio. The genset application rating can be set to either
Standby or Prime (default = Standby).
CT Ratio: The CT Ratio value must be set to
match the CT Ratio of the current transform- Standby kVA Rating Menu
ers on the genset (default = 150:5).
The kVA Rating menu displays the kVA rating of
MPU Enable: Displays whether or not the single-phase or three-phase, 50 or 60 hertz stand-
Magnetic Pickup Unit is installed (Yes or No, by genset systems. These value are used by the
default = No). control to determine what is 100% load. The values
must match the kVA rating of the genset application
Fly. Teeth: The total number of teeth pulses
and cannot be more than 2000 kVA.
per revolution on the flywheel (used for elec-
tronic governed systems) can be set from 0 3Ph/50Hz: The three phase, 50 Hertz rating
to 256 (default = 110). can be set from 0 to 2000 kVA (default = 25
kVA).
RPM/Hz Ratio: Allows for setting the Speed/
Frequency Ratio to 20, 30, or 60 RPM/Hz 3Ph/60Hz: The three phase, 60 Hertz rating
(default = 30). can be set from 0 to 2000 kVA (default = 25
kVA).
Genset Menu 2
1Ph/50Hz: The single phase, 50 Hertz rating
The second Genset Setup menu is used to set the can be set from 0 to 2000 kVA (default = 25
excitation source and the excitation/line frequency kVA).
gain.
1Ph/60Hz: The single phase, 60 Hertz rating
Excitation Source: Select Shunt or PMG Ex- can be set from 0 to 2000 kVA (default = 25
citation, depending upon your application. kVA).

5-39
GENSET SETUP SUBMENUS

CONTINUED ON
PAGE 5-42

FIGURE 5-19. GENSET SETUP SUBMENUS (SHEET 1 OF 3)

5-40
Prime kVA Rating Menu Battery Thresholds Menu
The kVA Rating menu displays the kVA rating of
single-phase or three-phase, 50 or 60 hertz prime The Battery Thresholds menu is used to set the low
genset systems. These value are used by the con- and high voltage values to determine when the bat-
trol to determine what is 100% load. The values tery voltage is out of the set range during normal
must match the kVA rating of the genset application operation. This menu is also used to determine
and cannot be more than 2000 kVA. when the battery voltage is below weak battery
thresholds during cranking. The Battery Thresh-
3Ph/50Hz: The three phase, 50 Hertz rating
olds menu that is displayed is dependent upon the
can be set from 0 to 2000 kVA (default = 25
battery voltage entered in the Battery Select menu.
kVA).
3Ph/60Hz: The three phase, 60 Hertz rating Low Batt: The low battery voltage threshold
can be set from 0 to 2000 kVA (default = 25 can be set from 11.0 to 13.0 VDC for 12 volt
kVA). batteries (default = 12.0 VDC) and from 22.0
1Ph/50Hz: The single phase, 50 Hertz rating to 27.0 VDC for 24 volt batteries (default =
can be set from 0 to 2000 kVA (default = 25 24.0 VDC), in 0.1 VDC increments.
kVA).
High Batt: The high battery voltage threshold
1Ph/60Hz: The single phase, 60 Hertz rating
can be set from 14.0 to 17.0 VDC for 12 volt
can be set from 0 to 2000 kVA (default = 25
batteries (default = 16.0 VDC) and from 28.0
kVA).
to 34.0 VDC for 24 volt batteries (default =
Battery Select Menu 32.0 VDC), in 0.1 VDC increments.

The Battery Select menu is used to set the nominal


battery voltage. Weak Batt: The weak battery voltage thresh-
old can be set from 6.0 to 10.0 VDC for 12
Nominal Battery Voltage: Allows for setting volt batteries (default = 8.0 VDC) and from
the nominal battery voltage (12 or 24V, de- 12.0 to 16.0 VDC for 24 volt batteries (de-
fault = 12V). fault = 14.4 VDC), in 0.1 VDC increments.

5-41
GENSET SETUP SUBMENUS (Continued)
A RETURN TO PAGE 5-40
B

12V 24V

OR

D D

C
CONTINUED ON
PAGE 5-44

FIGURE 5-19. GENSET SETUP SUBMENUS (SHEET 2 OF 3)

5-42
Battery Delay Setup Menu Oil Pressure Setup Menus

This menu is used to determine when, after deter- NOTE: The following menus are only available if
mining that the battery condition is out of the preset the the ECM CAN feature is disabled.
operating range, a warning message is an- A menu is available to set the sensor type. If the
nounced. sensor type is Switch, then another menu is avail-
able to set the sensor polarity. If the sensor type is
L. Batt TD: A time delay from 2 to 60 sec- Sender, then another menu is available to set the
onds (default = 60 seconds) can be set be- sender type.
fore the Low Battery warning message
(Fault Code 441) is announced. Sensor Type: The sensor type can be set for
either Switch or Sender (default = Switch).
H. Batt TD: A time delay from 2 to 60 sec-
Sensor Polarity: This menu is displayed only
onds (default = 60 seconds) can be set be-
if the sensor type is set to Switch. Sensor
fore the High Battery warning message
polarity can be set to either Active Low or
(Fault Code 442) is announced.
Active High (default = Active Low).
Wk Batt TD: A time delay from 1 to 5 sec- Sender Type: This menu is displayed only if
onds (default = 2 seconds) can be set before the sensor type is set to Sender. The sender
the Weak Battery warning message (Fault type can be set to either 2 Wire or 3 Wire
Code 1442) is announced. (default = 2 Wire).

5-43
GENSET SETUP SUBMENUS (Continued)

C RETURN TO PAGE 5-42


D

NOTE: These menus are available only


if the the ECM CAN feature is
disabled.

SWITCH SENDER
OR

FIGURE 5-19. GENSET SETUP SUBMENUS (SHEET 3 OF 3)

5-44
Voltage Protection Submenus Overfrequency Menu

The Voltage Protection submenus are available by This menu is used to determine when an overfre-
pressing the (2) button on the first Genset Setup quency fault condition exists and for how long the
menu (see Figure 5-17 or Figure 5-18). fault condition should be present before the engine
Figure 5-20 is a block representation of the four is shut down.
Voltage Protection submenus that are available. Overfrequency Threshold: This threshold is
High AC Voltage Menu used to set the amount of Hertz that the al-
ternator line frequency can be over to acti-
This menu is used to determine when a high AC vate an Overfrequency fault condition. This
voltage fault condition exists and for how long the value can be set from 2 to 10 Hz (default = 6
fault condition should be present before the engine Hz).
is shut down.
Overfrequency Delay: A time delay of 100 to
High AC Voltage Threshold: This threshold 2000 half cycles (default = 1100 half cycles)
is used to set the percentage of desired volt- must expire before the engine shuts down
age necessary to activate a High AC Voltage because of an overfrequency fault condition.
fault condition. This value can be set from If the fault condition is active for the duration
105 to 125% (default = 110%). of this time delay, the engine shuts down
High AC Voltage Time Delay: A time delay of and the Overfrequency shutdown message
1 to 10 seconds (default = 10 seconds) must (Fault Code 1449) is announced.
expire before the engine shuts down be-
Underfrequency Menu
cause of a high AC voltage fault condition. If
the fault condition is active for the duration of
This menu is used to determine when an underfre-
this time delay, the engine shuts down and
quency fault condition exists and for how long the
the High AC Voltage shutdown message
fault condition should be present before the engine
(Fault Code 1446) is announced.
is shut down.
Low AC Voltage Menu
Underfrequency Threshold: This threshold is
This menu is used to determine when a low AC used to set the Hertz number that the alter-
voltage fault condition exists and for how long the nator line frequency can be under to activate
fault condition should be present before the engine an Underfrequency fault condition. This val-
is shut down. ue can be set from 2 to 10 Hz (default = 6
Hz).
Low AC Voltage Threshold: This threshold is
used to set the percentage of desired volt- Underfrequency Time Delay: A time delay of
age necessary to activate a Low AC Voltage 500 and 2000 half cycles (default = 1100 half
fault condition. This value can be set from 50 cycles) must expire before the engine shuts
to 95% (default = 85%). down because of an underfrequency fault
condition. If the fault condition is active for
Low AC Voltage Time Delay: A time delay of
the duration of this time delay, the engine
2 to 20 seconds (default = 10 seconds) must
shuts down and the Underfrequency shut-
expire before the engine shuts down be-
down message (Fault Code 1448) is an-
cause of a low AC voltage fault condition. If
nounced.
the fault condition is active for the duration of
this time delay, the engine shuts down and
the Low AC Voltage shutdown message
(Fault Code 1447) is announced.

5-45
VOLTAGE PROTECTION SUBMENUS

FIGURE 5-20. VOLTAGE PROTECTION SUBMENUS

5-46
Alternator Protection condition should be present before the warning
message is displayed and, if necessary, the shut-
The alternator protection feature protects the alter- down message is displayed and the engine is shut
nator as well as connected loads from conditions of down.
High AC Voltage, Low AC Voltage, Loss of AC
Sense, Field Overcurrent, Overfrequency, Under- NOTE: If both the High Current Warning and High
frequency, and High AC Current. Current Shutdown faults are active at the
same time, the High Current Shutdown
Current Protection Submenus fault is displayed.
The Current Protection submenus are available by H. Curr Shutdown Time Delay: The High
pressing the (3) button on the first Genset Setup Current Shutdown Time Delay sets how long
menu (see Figure 5-17 or Figure 5-18). before the fault is greater than the instanta-
neous threshold. If the fault condition is ac-
Figure 5-21 is a block representation of the Current
tive for the duration of this time delay (2 to
Protection submenu.
60 seconds, default = 10 seconds), the en-
High AC Current Menu gine shuts down and the High AC Current
shutdown message (Fault Code 1472) is
This menu is used to determine how long the fault announced.

5-47
CURRENT PROTECTION SUBMENUS

FIGURE 5-21. CURRENT PROTECTION SUBMENUS

5-48
Engine Protection Submenus for how long the fault condition should be present
before the engine is shut down.
The Engine Protection submenus are available by
pressing the (4) button on the second Genset Set- Speed/Freq Fault Threshold: This threshold
up menu (see Figure 5-17 or Figure 5-18). is used to set the value necessary to acti-
vate the speed/frequency conflict shutdown
The Engine Protection submenus (see Figure fault condition. This value can be set from
5-22) are used to set thresholds to determine when 0.1 to 20.0 Hz (default = 2.0 Hz).
engine fault conditions exist and time delays to de-
Speed/Freq Fault Time Delay: A time delay
termine how long a fault condition is present before
of 0.2 to 10.0 seconds (default = 1 second)
the fault message is announced and, if necessary,
must expire before the warning message is
shut down the engine.
announced because of a speed/frequency
Engine Protection Overspeed Menu conflict shutdown fault condition. If the fault
condition is active for the duration of this
This menu is used to set the value necessary to time delay, the genset is shut down and the
shut down the genset and activate an Overspeed Speed Hz Match shutdown message (Fault
shutdown message (Fault Code 234) on 50 and 60 Code 1469) is announced.
Hz gensets, indicating that the engine has exceed- Low Oil Pressure Warning Menu
ed normal operating speed.
This menu is used to determine when a low oil
Overspeed (50Hz) Threshold: This threshold pressure warning fault condition exists and for how
is used to set the overspeed value neces- long the fault condition must be present before the
sary to activate an Overspeed shutdown warning message is announced.
fault condition on 50 Hz gensets. This value
can be set from 0 to 8192 RPM, in 25 RPM LOP Warning Threshold: This threshold is
increments (default = 1725 RPM). used to set the oil pressure value necessary
to activate a Pre-Low Oil Pressure warning
Overspeed (60Hz) Threshold: This threshold fault condition. This value can be set from 0
is used to set the overspeed value neces- to 100 PSig (default = 35 PSig).
sary to activate an Overspeed shutdown
fault condition on 60 Hz gensets. This value LOP Warning Time Delay: A time delay of 2
can be set from 0 to 24,096 RPM, in 25 to 15 seconds (default = 8 seconds) must
RPM increments (default = 2075 RPM). expire before the warning message is an-
nounced because of a low oil pressure warn-
Engine Protection Speed/Frequency Menu ing fault condition. If the fault condition is ac-
tive for the duration of this time delay, the
This menu is used to determine when a speed/fre- Pre-Low Oil Pressure warning message
quency conflict shutdown fault condition exists and (Fault Code 143) is announced.

5-49
ENGINE PROTECTION SUBMENUS
NOTE: These menus are available only
if the the ECM CAN feature is
disabled.

CONTINUED ON
PAGE 5-52

FIGURE 5-22. ENGINE PROTECTION SUBMENUS (SHEET 1 OF 3)

5-50
Low Oil Pressure Shutdown Menu set from 150 to 290 degrees F (default = 215
degrees F).
This menu is used to determine when a low oil
pressure shutdown fault condition exists and for HCT Warning Time Delay: A time delay of 2
how long the fault condition should be present be- to 10 seconds (default = 2 seconds) must
fore the engine is shut down. expire before the warning message is an-
nounced. If the fault condition is active for
LOP Shutdown Threshold: This threshold is the duration of this time delay, the High
used to set the oil pressure value necessary Coolant Temperature warning message
to activate a Low Oil Pressure Shutdown (Fault Code 146) is announced.
fault condition. This value can be set from 0
High Coolant Temperature Shutdown Menu
to 100 PSig (default = 30 PSig).
This menu is used to determine when a high cool-
LOP Shutdown Time Delay: A time delay of
ant temperature shutdown fault condition exists
2 to 15 seconds (default = 8 seconds) must
and for how long the fault condition should be pres-
expire before the engine shuts down be-
ent before the engine is shut down.
cause of a low oil pressure fault condition. If
the fault condition is active for the duration of HCT Shutdown Threshold: This threshold is
this time delay, the engine shuts down and used to set the temperature value necessary
the Low Oil Pressure shutdown message to activate a High Coolant Temperature
(Fault Code 415) is announced. Shutdown fault condition. This value can be
set from 180 to 300 degrees F (default = 223
High Coolant Temperature Warning Menu degrees F).

This menu is used to determine when a high cool- HCT Shutdown Time Delay: A time delay of
ant temperature warning fault condition exists and 2 to 10 seconds (default = 2 seconds) must
for how long the fault condition should be present expire before the engine shuts down be-
before the warning message is announced. cause of a high coolant temperature fault
condition. If the fault condition is active for
HCT Warning Threshold: This threshold is the duration of this time delay, the engine
used to set the temperature value necessary shuts down and the High Coolant Tempera-
to activate a High Coolant Temperature ture shutdown message (Fault Code 151) is
Warning fault condition. This value can be announced.

5-51
ENGINE PROTECTION SUBMENUS (Continued)

NOTE: These menus are available only


if the the ECM CAN feature is
disabled.

RETURN TO PAGE 5-50


A B

CONTINUED ON
PAGE 5-54

FIGURE 5-22. ENGINE PROTECTION SUBMENUS (SHEET 2 OF 3)

5-52
Engine Protection Low Coolant Temperature Charger Failed H Threshold: This threshold
and Battery Charger Menus is used to set the high charging alternator
voltage value. This value can be set from
The low coolant temperature menu is used to de- 13.0 to 20.0 VDC (default = 18.0 VDC) for
termine when the gensets coolant temperature is 12V units and from 25.0 to 40.0 VDC (de-
too low and a Low Coolant Temperature warning fault = 32.0 VDC) for 24V units.
message (Fault Code 1435) is announced. This
warning message is not announced unless the
coolant temperature has been determined to be Charger Failed L Threshold: This threshold
low for one minute. is used to set the low charging alternator
voltage value. This value can be set from 2.0
LCT Warning Threshold: This threshold is to 13.0 VDC (default = 5.0 VDC) for 12V
used to set the temperature value necessary units and from 2.0 to 25.0 VDC (default =
to activate a Low Coolant Temperature 10.0 VDC) for 24V units.
Warning fault condition. This value can be
set from 32 to 100 degrees F (default = 70
Charger Failed Time Delay: A time delay of
degrees F).
2 to 300 seconds (default = 120 seconds)
The battery charger menu is used to determine must expire before the warning message is
when the alternator charger failure condition exists announced. If the fault condition is active for
and when the warning message should be an- the duration of this time delay, the Charger
nounced. The fault condition exists when either the Failure warning message (Fault Code 2678)
low or high threshold is reached. is announced.

5-53
ENGINE PROTECTION SUBMENUS (Continued)

NOTE: These menus are available only


if the the ECM CAN feature is
disabled.

RETURN TO PAGE 5-52


C
D

FIGURE 5-22. ENGINE PROTECTION SUBMENUS (SHEET 3 OF 3)

5-54
6. Troubleshooting
INTRODUCTION vice tool is used to update (enable) that feature.
Confirm that the feature is installed and enabled
The 1302 series control continuously monitors en- prior to troubleshooting the base board for symp-
gine sensors for abnormal conditions, such as low toms related to a feature.
oil pressure and high coolant temperature. If any of
these conditions occur, the control (with graphical NETWORK APPLICATIONS AND
display) will light a yellow warning lamp or a red CONFIGURABLE INPUTS
shutdown lamp and display a message on the In applications with networks and remote configur-
graphical display. A control without the graphical able inputs, the genset may start unexpectedly or
display indicates a shutdown condition by intermit- fail to crank as a result of these inputs. These
tent flashing of the status indicator. symptoms may appear to be caused by the base
When the control is paired with a Cummins ECM on board. Verify that the remote input is not causing
Full Authority Electronic the local engine inputs are the symptom or isolate the control from these in-
ignored. Instead, the control receives all engine re- puts before troubleshooting the control.
lated faults and messages from the ECM. Fault SAFETY CONSIDERATIONS
codes are still shown on the HMI or status indicator
as if they were local to the PCC1302 controller. WARNINGContacting high voltage compo-
nents can cause electrocution, resulting in se-
PC BASED SERVICE TOOL vere personal injury or death. Keep the output
box covers in place during troubleshooting.
The PC based service tool can be used in trouble-
shooting to perform tests, verify control inputs and WARNING Ignition of explosive battery gases
outputs, and test protective functions. can cause severe personal injury or death. Arc-
ing at battery terminals, light switch or other
When used improperly, a PC based service tool equipment, flame, pilot lights and sparks can
can cause symptoms like warnings and shutdowns ignite battery gas. Do not smoke, or switch
that appear to be a defective base board. When trouble light ON or OFF near battery. Discharge
these problems occur, always verify that a self-test static electricity from body before touching
or fault simulation (override) have not been left en- batteries by first touching a grounded metal
abled with the tool. If you do not have a PC based surface.
service tool, or the enabled fault simulation(s) can
not be found using the tool, disconnect battery Ventilate battery area before working on or
power to disable the test or override condition. near batteryWear gogglesStop genset and
disconnect charger before disconnecting bat-
Make sure that parameter adjustments and time tery cablesDisconnect negative () cable
delays, related to the fault condition, have been ap- first and reconnect last.
propriately set for the application. It may be neces- CAUTION Disconnect battery charger from
sary to write the initial capture file to the device or
AC source before disconnecting battery
update the calibration file. Updating a calibration
cables. Otherwise, disconnecting cables can
file requires the a pro version of many of PC based
result in voltage spikes damaging to DC control
service tools. Confirm that the installed calibration
circuits of the genset.
part number matches the serial plate information.
WARNING Accidental starting of the genera-
CAUTION Using the wrong calibration file tor set can cause severe personal injury or
can result in equipment damage. Do not swap death. Prevent accidental starting by discon-
Base boards from another genset model and necting the negative () cable from the battery
only use the calibration file shown on the terminal.
nameplate.
When troubleshooting a generator set that is shut
Some features are not available until the hardware down, make certain the generator set cannot be
for that feature is installed and the PC based ser- accidentally restarted as follows:

6-1
1. For installations without the optional operator Warning fault codes are not displayed by the status
panel: Move the Start/Off/Auto switch on the indicator lamp. A PC based service tool is needed
control panel to the OFF position. to read warning fault codes.
The following describes how to interpret the status
2. For installations with the optional operator
indicator light.
panel: Press the button (0) to switch the con-
trol into the Off mode. Do not move the control switch to the OFF posi-
tion before interpreting the fault code. Moving
3. Turn off or remove AC power from the battery the switch to OFF will clear the fault indication.
charger.
Constant Rate Flashing = Engine preheat
/genset starting.
4. Remove the negative () battery cable from
the generator set starting battery. Constant On = Genset running.
Variable Rate Flashing = A genset Shutdown
READING FAULT CODES fault condition exists (Warning conditions are
not displayed). All of the Shutdown faults
If the genset contains the graphical display and a described in section 14 can be announced
fault occurs, the fault code/message can be viewed with the status indicator lamp.
in the display. If the control does not contain the
graphical display, the fault code is read from the An example of a four digit fault code first digit in
control switch indicator. the code is flashed, followed by a halfsecond
pause, and then the second digit is flashed, fol-
After the fault is acknowledged and corrected, the lowed by a halfsecond pause, followed by a half
recorded fault will be deleted from the control panel second pause, and then the third digit is flashed,
memory, but will remain in a data log to maintain a followed by a halfsecond pause, and then the
fault code history and fault code occurrence table. fourth digit is flashed, followed by a one second
A PC-based service tool is required to view this pause.
data log.
TROUBLESHOOTING PROCEDURES
Reading Fault Codes Using Optional
Operator Panel The following tables are a guide to help you evalu-
ate problems with the generator set. You can save
The warning or shutdown LED will light and the time if you read through the manual ahead of time
fault symbol, and code will be displayed on the dis- and understand the system.
play. Refer to the Fault Code List in the Protection Voltage/Continuity Testing
and Faults section for the exact name of the fault.
Voltage and continuity tests are required in the fol-
Reading Fault Codes Using the Control lowing tables. In some cases, it is necessary to re-
Switch Indicator move a plug to complete the test. Where required,
the corrective action will mention when it is neces-
1302 series control without display): The control sary to remove a plug for testing. In other cases,
panel rocker switch contains a status indicator the plug cannot be removed for testing. When plug
lamp. This lamp is used to flash genset status and removal is not mentioned, testing must be per-
shutdown fault codes. (Only the last shutdown fault formed by inserting a narrow meter probe into the
code is flashed.) back of the plug.

6-2
TABLE 6-1. ENGINE DOES NOT CRANK IN MANUAL MODE (NO FAULT MESSAGE)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: This indicates that the control has not received or recognized a manual start signal.
Effect: Engine will not start.
POSSIBLE CAUSE CORRECTIVE ACTION
ENGINE PLATFORM FAE Engines HM Engines
No power supplied to the 1. Check wakeup conditions. 1. Check wakeup conditions.
control due to poor bat-
2. Check for poor battery cable connec- 2. Check for poor battery cable connec-
tery cable connections.
tions. Clean the battery cable termi- tions. Clean the battery cable termi-
Clean the battery cable nals and tighten all connections. nals and tighten all connections.
terminals and tighten all
3. Remove connector P20 and check for 3. Remove connector P20 and check for
connections.
B+ at P20-9 and P20-10 and GND at B+ at P20 and P20-10 and GND at
P20-2 and P20-4. If B+ or ground is P20-2. If B+ or ground missing, iso-
missing, isolate to the harness and late to harness and TB BAT terminal
the TB BAT terminal mounted on the mounted on engine block. If B+ and
engine block. If B+ and ground check ground check OK, cycle power to
OK, cycle power to Base board by re- Base board by reconnecting P20 and
connecting P20 and retry operation. retry operation.
1302 series control Check for B+ at TB1-5 and GND at Check for B+ at TB1-5 and GND at
with display: No power TB1-3. If ground is missing, the Base TB1-3. If ground is missing, the Base
supplied to front mem- board is defective and must be replaced. board is defective and must be replaced.
brane panel. If B+ is missing, then: If B+ is missing, then:
1. If B+ and ground check are OK, re- 1. If B+ and ground check are OK, re-
move P1 from the back of the front move P1 from the back of the front
membrane panel. membrane panel.
2. Check for B+ at P1-3 and ground at 2. Check for B+ at P1-3 and ground at
P1-5. If B+ or ground is missing, re- P1-5. If B+ or ground is missing, re-
pair the harness. pair the harness.
Base board not properly Confirm that the installed calibration part Confirm that the installed calibration part
calibrated or corrupt cal- number matches the serial plate informa- number matches the serial plate informa-
ibration. tion. Re-enter the calibration file if neces- tion. Re-enter the calibration file if neces-
sary. sary.
The Remote Emergency With Emergency Stop push button not ac- With Emergency Stop push button not ac-
Stop switch or wiring is tivated (switch closed), remove configur- tivated (switch closed), remove configur-
defective. able leads from TB1-15 and TB1-16 and able leads from TB1-15 and TB1-16 and
check for continuity between these two check for continuity between these two
leads. If circuit is open, isolate to Emer- leads. If circuit is open, isolate to Emer-
gency Stop switch and wiring. If there is gency Stop switch and wiring. If there is
continuity, go to the next step. continuity, go to the next step.

6-3
TABLE 6-1. ENGINE DOES NOT CRANK IN MANUAL MODE (NO FAULT MESSAGE) (CONT.)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: This indicates that the control has not received or recognized a manual start signal.
Effect: Engine will not start.
POSSIBLE CAUSE CORRECTIVE ACTION
ENGINE PLATFORM FAE Engines HM Engines
The Local Emergency With the Emergency Stop push button not With the Emergency Stop push button not
Stop switch or wiring is activated (switch closed), check for conti- activated (switch closed), check for conti-
defective. nuity between J25-2 and J25-6. If the cir- nuity between J25-2 and J25-6. If the cir-
cuit is open, isolate to the Emergency cuit is open, isolate to the Emergency
Stop switch and wiring. If there is continu- Stop switch and wiring. If there is continu-
ity, go to the next step. ity, go to the next step.
1302 series control Remove connector P25 from the Base Remove connector P25 from the Base
without display: The board. With Start switch in the Manual board. With the Start switch in the Manual
Manual input signal is not position, check for continuity between position, check for continuity between
getting from the Manual P25-10 (RUN) to P25-8 (GND). If there is P25-10 (RUN) to P25-8 (GND). If there is
select switch (S12) to the no continuity, isolate to the switch and no continuity, isolate to the switch and
Base board, indicting that wiring. If there is continuity, the Base wiring. If there is continuity, the Base
the S12, Base board, or board is defective and needs to be re- board is defective and needs to be re-
the harness is defective. placed. placed.
1302 series control Check for continuity between P25-10 Check for continuity between P25-10
with display: The menu (RUN) to P25-8. If there is no continuity (RUN) to P25-8. If there is no continuity
display Manual Run but- when pressing the Manual Run button, when pressing the Manual Run button,
ton, harness, or the Base isolate to the front membrane panel and isolate to the front membrane panel and
board is defective. wiring. If there is continuity, the Base wiring. If there is continuity, the Base
board is defective and needs to be re- board is defective and needs to be re-
placed. placed.
Oil Pressure switch or 1. Remove the P11 connection and
wiring is defective check wiring between P11-2 and
P11-3 to the switch.
2. Verify control is configured for the
type of switch installed.
3. Verify proper operation of the switch.
Oil Pressure sender, set- 1. Remove the P11 connection and
up on wiring is defective. check wiring between P11-1, P11-2,
and P11-3 (for 3-wire sender) to the
sender.
2. Verify that the control is configured for
the correct type of sender (see Figure
5-19, sheet 3).
3. Verify operation of the sender.
CAN Datalink Failed Refer to Fault Code 427 or 781.

6-4
TABLE 6-2. ENGINE DOES NOT CRANK IN REMOTE MODE (NO FAULT MESSAGE)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: This indicates that the 1302 series control has not received or recognized a remote start signal.
Effect: Engine will not start in Remote mode, but starts in manual mode.
POSSIBLE CAUSE CORRECTIVE ACTION
The remote start switch or confi- 1. Reset the control. Attempt to start the engine and check for ground at
gurable wiring is defective. TB1-11.
2. If ground level is not present, isolate to the remote switch or configurable
wiring. Repair as necessary.
3. If ground is present, go to the next step.
1302 series control without 1. Remove connector P11 from the Base board.
display: The Auto mode input is
2. With S12 in Auto position, check for continuity from P25-11 (AUTO) to
not getting from the Auto Select
P25-8 (GND).
switch to the Base board, indict-
ing that S12, the Base board, or 3. If there is no continuity, isolate to the switch or the wiring harness. If there
the harness is defective. is continuity, the Base board is defective and must be replaced.
1302 series control with dis- 1. Check for continuity between P25-11 (AUTO) and P25-8 (GND).
play: The menu display Auto
2. If there is no continuity when pressing the menu display Auto button, iso-
button, harness, or the Base
late to the front membrane panel or the wiring harness. If there is continu-
board is defective.
ity, the Base board is defective and must be replaced.
For more information, see Table 6-1, Will Not Crank in Manual Mode.

6-5
TABLE 6-2. WARNING AND SHUTDOWN CODES
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
FAULT CODE CORRECTIVE ACTION
ENGINE PLATFORM FAE Engines HM Engines
121 Not applicable on FAE engines. Indicates that no magnetic pickup pulses
SPEED SIGNAL LOST are sensed for a Loss of Speed delay. If a
Lamp: Shutdown magnetic pickup is not installed, then
speed sensing is performed by monitoring
AC line frequency and this fault cannot
occur.
141. 135 Indicates that the engine controller has Indicates that the control has sensed that
OIL PRESS SENSOR sensed that the engine oil pressure sen- the engine oil pressure sensor output is
OOR L/H sor output is out of range (high or low). out of range (high or low). Check the
Lamp: Warning Consult the engine service manual and sender/connectors/wires. This warning
check the sender/connectors/wires. will only occur if the genset is equipped
with an oil pressure sender.
143 Indicates the engine oil pressure has Indicates the engine oil pressure has
PRE-LOW OIL dropped below the warning trip point pro- dropped below the warning trip point. If
PRESSURE grammed into the engine controller. If the the generator is powering critical loads
Lamp: Warning generator is powering critical loads and and cannot be shut down, wait until the
cannot be shut down, wait until the next next shutdown period and then follow the
shutdown period and then follow the Fault Code 415 procedure. This warning
Fault Code 415 procedure. will only occur if the genset is equipped
with an oil pressure sender.
144, 145 Indicates that the engine controller has Indicates that the control has sensed that
COOL SENSOR OOR sensed that the engine coolant tempera- the engine coolant temperature sensor
LOW/HIGH ture sensor output is out of range (high or output is out of range (high or low). Check
Lamp: Warning low). Consult the engine service manual the sender/connectors/wires.
and check the sender/connectors/wires.
146 Indicates the engine is operating near its Indicates the engine is operating near its
PRE-HIGH COOL TMP cooling system capacity. An increase in cooling system capacity. An increase in
Lamp: Warning load or higher ambient temperature may load or higher ambient temperature may
cause a High Coolant Temp shutdown. cause a High Coolant Temp shutdown.
Review Fault Code 151 correction list for Review Fault Code 151 correction list for
other possible causes. other possible causes.

6-6
TABLE 6-2. WARNING AND SHUTDOWN CODES (CONT.)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
FAULT CODE CORRECTIVE ACTION
ENGINE PLATFORM FAE Engines HM Engines
151 Indicates the engine has overheated Indicates the engine has overheated
HIGH COOLANT TEMP (coolant temperature has risen above the (coolant temperature has risen above the
Lamp: Shutdown shutdown trip point set at the engine con- shutdown trip point).
troller). Allow the engine to cool down completely
Allow the engine to cool down completely before proceeding with the following
before proceeding with the following checks:
checks:
1. Check the coolant level and replenish
1. Consult the engine service manual if low. Look for possible coolant leak-
and reset the PCC1302. age points and repair if necessary.
2. Restart the generator after locating 2. Check for obstructions to the cooling
and correcting the problem. airflow and correct as necessary.
3. Check the fan belt and repair or tight-
en if necessary.
4. Check the blower fan and circulation
pumps on remote radiator installa-
tions.
5. Reset the control and restart the gen-
erator after locating and correcting
the problem.
415 Indicates the engine oil pressure has Indicates the engine oil pressure has
LOW OIL PRESSURE dropped below the shutdown trip point dropped below the shutdown trip point.
Lamp: Shutdown programmed into the engine controller.
1. Check the oil level, lines, and filters.
1. Consult the engine service manual
2. If the oil system is OK but the oil level
and reset the control.
is low, replenish.
2. Restart the generator after locating
3. Reset the control and restart the gen-
and correcting the problem.
set.
4. If an oil switch is used, check switch
performance.
234 Indicates the engine has exceeded nor- Indicates engine has exceeded normal
OVERSPEED mal operating speed. The default thresh- operating speed. The default thresholds
Lamp: Shutdown olds are preprogrammed in the engine are 1725 RPM (50 Hz) or 2075 RPM (60
controller. An engine service tool such as Hz).
Insite or CalTerm III is required to change
Possible causes are single step large
threshold settings.
block load removal or flammable vapors
Possible causes are single step large drawn into the intake air passage. Reset
block load removal or flammable vapors the control and restart after locating and
drawn into the intake air passage. Reset correcting the problem.
the control and restart after locating and
correcting the problem.

6-7
TABLE 6-2. WARNING AND SHUTDOWN CODES (CONT.)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
FAULT CODE CORRECTIVE ACTION
ENGINE PLATFORM FAE Engines HM Engines
359 Indicates a possible fuel system or air in- Indicates a possible fuel system or air in-
FAIL TO START duction problem. (Engine cranks but fails duction problem. (Engine cranks but fails
Lamp: Shutdown to start) to start)
Consult the engine service manual for 1. Check for an empty fuel tank, fuel
possible causes / solutions. leaks, or plugged fuel lines and cor-
rect as required.
2. Check for a dirty fuel filter and re-
place if necessary.
3. Check for a dirty or plugged air filter
and replace if necessary.
4. Reset the control and restart after
correcting the problem.
441 Indicates the battery voltage supply to the control is approaching a low level at which
LOW BATTERY an unpredictable operation will occur.
Lamp: Warning
1. Discharged or defective battery.
Check the battery charger fuse.
Recharge or replace the battery.
2. Check for poor battery cable connections. Clean the battery cable terminals and
tighten all connections.
3. Check the battery wiring/calibration.
4. Check the engine DC alternator. Replace the engine DC alternator if normal bat-
tery charging voltage is not obtained.
5. Check the battery charge voltage float level if applicable (raise float level).
442 Indicates the battery voltage supply to the control is approaching a high level at which
HIGH BATTERY damage to the control can occur. Check the float level on the battery charger if appli-
Lamp: Warning cable (lower float level).
Check battery wiring/calibration.
1123 A shutdown fault occurred while the Battle Short mode was enabled. Check the fault
SHUTDOWN AFTER history (see Figure 4-18) for faults that may have been bypassed.
BATTLESHORT
Lamp: Shutdown
1131 Indicates that the control is in Battle Short mode used to bypass several fault shut-
BATTLE SHORT downs, therefore allowing genset operation during emergencies.
ACTIVE
Lamp: Warning
1311, 1312, 1317, 1318 The nature of the fault is an optional configurable selection. Example inputs: Low Fuel
CONFIGURABLE INPUT Day Tank, Water In Fuel, Ground Fault, etc.
1, 2, 3, 4
Each of the fault functions can be programmed (using a service tool or the operator
Lamp: Configurable
panel), as follows:
Event or Warning or Shutdown level if Function Select = Fault Input
Change the display name using up to 32 characters.

6-8
TABLE 6-2. WARNING AND SHUTDOWN CODES (CONT.)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
FAULT CODE CORRECTIVE ACTION
ENGINE PLATFORM FAE Engines HM Engines
1416 The genset continues to run after receiving a shutdown command from the controller.
FAIL TO SHUTDOWN The Battle Short feature is enabled this is used to bypass several critical fault shut-
Lamp: Warning downs, therefore allowing genset operation during emergencies.
1433 Indicates a Remote Emergency Stop. To reset the Remote Emergency Stop button:
REMOTE EMERGENCY
1. Close (disable) the remote Emergency Stop button.
STOP
Lamp: Shutdown 2. Move the control switch to the OFF position or press the OFF button.
3. Select the desired operating mode (Manual or Auto).
If the application has a remote fault reset, the fault can also be reset by closing the
fault reset switch.
1434 Indicates a Local Emergency Stop. To reset the Local Emergency Stop button:
LOCAL EMERGENCY
1. Close (disable) Local Emergency Stop button.
STOP
Lamp: Shutdown 2. Move the control switch to the OFF position or press the OFF button.
3. Select the desired operating mode (Manual or Auto).
If the application has a remote fault reset, the fault can also be reset by closing the
fault reset switch.
1435 Indicates the engine coolant heater is not operating or is not circulating coolant.
LOW COOLANT TEMP
Check for the following conditions:
Lamp: Warning
The coolant heater is not connected to the power supply. Check for a blown fuse
Set is not operating.
or a disconnected heater cord and correct as required.
Warning occurs when en-
gine coolant temperature Check for low coolant level and replenish if required. Look for possible coolant
is 70_F (21_C) or lower. leakage points and repair as required.
NOTE: In applications Check for an open heater element. Check the heaters current draw.
where the ambient tem-
perature falls below The coolant temperature must be below 70_F (default setting) for one minute to acti-
40_F (4_C), Low Cool- vate a warning and must be above 70_F for one minute before the warning is cleared.
ant Temp may be indi-
cated even though the
coolant heaters are op-
erating.
1438 The control has failed to receive engine The genset has failed to sense rotation
FAIL TO CRANK speed from ECM during cranking. Consult for two start attempts. This indicates a
Lamp: Shutdown the engine service manual for MPU diag- possible fault with the control, speed
nostic. See Fault Code 427 or 781 for sensing, or starting system. This fault can
datalink health diagnostic. only occur in gensets with a magnetic
pickup installed and enabled.
1442 Indicates that during cranking, the battery voltage is at or below the weak battery
WEAK BATTERY warning trip point for a time greater than or equal to the weak battery set time.
Lamp: Warning
1446 Indicates that one or more of the line-to-neutral phase voltages has exceeded 130%
HIGH AC VOLTAGE of nominal for 0 second, or has exceeded high AC voltage threshold of nominal for
Lamp: Shutdown time delay seconds.

6-9
TABLE 6-2. WARNING AND SHUTDOWN CODES (CONT.)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
FAULT CODE CORRECTIVE ACTION
ENGINE PLATFORM FAE Engines HM Engines
1447 Indicates that one or more of the line-to-neutral phase voltages has dropped below
LOW AC VOLTAGE low the AC voltage threshold for time delay seconds.
Lamp: Shutdown
1448 Indicates that the genset frequency has dropped below 90% of nominal for approxi-
UNDER FREQUENCY mately 10 seconds.
Lamp: Shutdown
Check the fuel supply, intake air supply, and load.
1449 Indicates frequency is 10% above base frequency for approximately 10 seconds.
OVER FREQUENCY
Lamp: Shutdown
1469 Not Applicable on FAE engines. Indicates that the measured speed and
SPEED HZ MATCH the measured AC output frequency do not
Lamp: Shutdown agree.
Check the genset setup for number of fly-
wheel teeth (see Figure 5-19, sheet 1).
1471 Indicates that an individual phase of alternator output current has exceeded the high
HIGH AC CURRENT current threshold of the rated output current continuously for more than the set time
Lamp: Shutdown delay.
Check the load and load lead connections.
1472 Indicates that one or more of the phase currents has exceeded the high AC warning
HIGH AC CURRENT threshold for the set time delay seconds.
Lamp: Warning
Check the load and load lead connections.
1853, 1854, 1855 The nature of the annunciator fault is an optional configurable selection.
ANNUNCIATOR
FAULT 1, 2, 3
Lamp: Configurable
1944 Indicates a mismatch in the configuration of one of the annunciator relay outputs.
ANNUNCIATOR OUT-
PUT CONFIGURATION
ERROR
Lamp: Warning
2335 Indicates a loss of zero cross detection. Check alternator voltage sense and excitation
LOSS OF AC SENSE leads for shorts or opens. Check load for shorts.
Lamp: Shutdown
2676 Indicates the alternator line frequency and alternator excitation frequency do not
ALTERNATOR FRE- match.
QUENCY CONFLICT
1. Check the Alternator Frequency Gain trim using the Operator Panel (see Figure
Lamp: Shutdown
5-19, sheet 1) or InPower.
2. Measure the alternator line frequency (J22-1 to J22-4). Measure the alternator
excitation frequency (J18-1 to J18-2). The alternator line frequency * Alternator
Frequency Gain should equal the excitation frequency. The alternator line fre-
quency and alternator excitation frequency are also viewable with InPower.
3. Check voltage sense leads and excitator power lead for open or shorts.

6-10
TABLE 6-2. WARNING AND SHUTDOWN CODES (CONT.)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
FAULT CODE CORRECTIVE ACTION
ENGINE PLATFORM FAE Engines HM Engines
2677 Genset continues to run after receiving Genset continues to run after receiving a
FAIL TO STOP shutdown command from the controller. shutdown command from the controller.
Lamp: Shutdown
The keyswitch relay is the what the Check for a stuck fuel actuator and fuel
PCC1302 uses to tell the engine control- shutoff valve.
ler to stop. Check the keyswitch relay op-
eration and make sure it isnt stuck
closed. Activating either emergency stop
switch should open the keyswitch relay.
Consult the engine service manual for
other possible causes / solutions.
2678 Indicates the battery charging alternator has not reached an acceptable voltage range
CHARGER FAILURE within the selected period (default = 120 seconds). Refer to the engine service manu-
Lamp: Warning al if this fault occurs. If not failed, check wiring.
2972 Indicates that the Field AVR Duty Cycle has been at the maximum for at least 15 sec-
FIELD OVERLOAD onds.
Lamp: Shutdown

6-11
TABLE 6-3. CODE 121 SPEED SIGNAL LOST (SHUTDOWN) GENSETS WITH MPU

WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: This indicates that the control is not sensing the magnetic pickup signal.
Effect: Engine will shut down.
POSSIBLE CAUSE CORRECTIVE ACTION
1. There are loose or Inspect the wires/connector pins and repair or replace as necessary.
damaged magnetic
pickup (MPU) wires/
connector pins.
2. The magnetic pickup, To isolate the problem, reset the control and attempt to start the genset.
harness or Base
If Fault Code 1438 (Fail To Crank) is displayed, or if the engine starts, but then shuts
board is defective.
down on Fault Code 121 (Speed Signal Lost), the MPU sender could be defective.
Remove the MPU connectors and check for 3.5 to 15 VAC at the MPU while cranking.
If there is no output, check for damage or debris. Also check for improper adjust-
ment of the MPU. If there is still no output, replace the MPU sender.
If the MPU output is OK, check for MPU voltage at P11-9 (MAG PICK+) to P11
10 (MAG PICK) while cranking. If OK, replace the Base board. If not OK, use
continuity checks to isolate connectors/harness.
If the engine starts and idles, and does not display a fault, then there could be a fre-
quency mismatch problem. Measure the generator output frequency with a digital
multimeter and compare to the frequency shown on the operator panel or the PC
based service tool.
Verify that the number of flywheel teeth has been correctly configured (see Fig-
ure 5-19, sheet 1 for information on how to adjust the flywheel tooth setting using
the operator panel).
If they do match, multiply the frequency by Speed/Freq Gain Select trim (typically
30) and compare this number to the RPM on the operator panel or PC based
service tool. If these are not the same, the MPU sender may be defective. Re-
place the MPU sender.
If the multimeter and control frequencies do not match, there is a frequency
sensing problem within the Base board. Replace the Base board.
3. Restricted fuel sup- In order to fix the problem, you need to make sure that there is an adequate fuel sup-
ply. The engine may ply that is free of clogs or leaks.
fire once during
cranking which could
cause the engine to
speed up past the
starter disconnect
speed. Due to the re-
stricted fuel supply,
the engine will not
turn over anymore
and the 1302 control
panel will display
fault code 121 once
the engine stops
spinning.

6-12
TABLE 6-4. CODE 135/141 OIL PRESSURE SENSOR OOR HIGH/LOW (WARNING)

WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: This indicates that the engine oil pressure sensor signal is out of range shorted high or low.
Effect: There is no engine protection for oil pressure during genset operation.

POSSIBLE CAUSE CORRECTIVE ACTION

ENGINE PLATFORM FAE Engines HM Engines

The sensor connections Consult the engine service manual. Inspect the sensor and engine harness
could be defective. connector pins. Repair or replace as nec-
essary.

The sensor could be de- Consult the engine service manual. Disconnect the oil pressure sensor leads
fective. and connect an oil pressure sensor simu-
lator to the harness.
An OIL PRESSURE SENSOR OOR
warning is displayed after the fault
condition is sensed for 10 seconds.
If the control responds to the simulator,
replace the sensor. If the control does not
respond, go to the next step.

The harness could be Consult the engine service manual. 1. Remove connector P11 from the
defective. Base board and the connector from
the sensor.
2. Check P11-1, 2 & 3 as follows:
Check for a short circuit from pin
to pin (more than 200k ohms is
OK).
Check for an open circuit (10
ohms or less is OK).
3. Repair or replace as necessary.

The Base board could be Consult the engine service manual. With all connectors attached, check the
defective. pressure signal (.5 to 4.5 VDC) at P11-3
(OP OUT) and P11-2 (OP COM). If within
range, replace the Base board.

TABLE 6-5. CODE 143 PRE-LOW OIL PRESSURE (WARNING)

WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: The engine oil pressure has dropped below the warning/shutdown threshold for pre-low oil pressure.
Effect: No action is taken by the control.
POSSIBLE CAUSE CORRECTIVE ACTION
Refer to Fault Code 415. Refer to Fault Code 415.

6-13
TABLE 6-6. CODE 143/415 LOW OR PRE-LOW OIL PRESSURE (WARNING/SHUTDOWN)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: Engine oil pressure has dropped below the warning/shutdown threshold for low/high oil pressure.
Effect: Calibration-dependent. No action is taken by the Control for Fault Code 143. Engine will shut down for
Fault Code 415.
POSSIBLE CAUSE CORRECTIVE ACTION
ENGINE PLATFORM FAE Engines HM Engines
Fault simulation was en- With a PC based service tool, verify that the fault simulation is not enabled for the oil
abled with a PC based pressure sensor.
service tool.
If you do not have a PC based service tool, remove battery power from the control to
disable the fault simulation overrides.
Low oil level. Clogged Check the oil level, lines, and filters. If the oil system is OK but the oil level is low, re-
lines or filters. plenish.
The sensor or oil pump Consult the engine service manual. Disconnect the oil pressure sensor leads
could be defective. Or and connect an oil pressure sensor simu-
the generator set may be lator to the harness.
shutting down on another
1. If the control responds to the simula-
fault.
tor, reconnect the sensor, disconnect
the + signal wire at the fuel solenoid,
and crank the engine.
Check the oil pressure reading on the
digital display.
If the display shows an accept-
able oil pressure, the problem
may not be in the oil or oil sens-
ing system. The genset may be
shutting down on another fault
(out of fuel, intermittent connec-
tor). Restart the genset and
monitor the display panel for oth-
er faults.
If the display does not show an
acceptable oil pressure, replace
the sensor. If the Control still
doesnt display an oil pressure
while cranking, the oil pump may
be defective. Refer to the engine
service manual.
2. If the control does not respond to the
simulator, go to the next step.

6-14
TABLE 6-6. CODE 143/415 LOW OR PRE-LOW OIL PRESSURE (WARNING/SHUTDOWN) (CONT.)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: Engine oil pressure has dropped below the warning/shutdown threshold for low/high oil pressure.
Effect: Calibration-dependent. No action is taken by the Control for Fault Code 143. Engine will shut down for
Fault Code 415.
POSSIBLE CAUSE CORRECTIVE ACTION
ENGINE PLATFORM FAE Engines HM Engines
Harness or Base board Consult the engine service manual. If the control does not respond to the sim-
could be defective. ulator, the Base board or the harness is
defective.
Check for +5 VDC at the sensor
(lead marked S1). If there is no
5 VDC at the sensor:
Check for 5 VDC at P11-1.
If present, the harness is defective and
must be replaced. If not present, the
Base board is defective and must be re-
placed.
If there is 5 VDC at the sensor, use the
sensor simulator to generate a signal to
P11-3 (Oil Sense) and P11-2 (Oil
Comm.). If the pressure signal (0.5 to
4.5 VDC) does not get to P11, isolate to
the harness. If the pressure signal does
go to P11, the Base board is defective
and must be replaced.
Low Oil Pressure fault Consult the engine service manual. Verify set points against the normal oper-
set points could be incor- ating pressures of the engine. Refer to
rect. the engine service manual.

TABLE 6-7. CODE 145/144 COOLANT SENSOR OOR HIGH/LOW (WARNING)


WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: This indicates that the coolant temperature sensor signal is out of range shorted high or low.
Effect: No engine protection for coolant temperature during genset operation. Possible white smoke.
POSSIBLE CAUSE CORRECTIVE ACTION
ENGINE PLATFORM FAE Engines HM Engines
The sensor connections Consult the engine service manual. Inspect the sensor and engine harness
could be defective. connector pins. Repair or replace as nec-
essary.

6-15
TABLE 6-7. CODE 145/144 COOLANT SENSOR OOR HIGH/LOW (WARNING) (CONT.)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: This indicates that the coolant temperature sensor signal is out of range shorted high or low.
Effect: No engine protection for coolant temperature during genset operation. Possible white smoke.
POSSIBLE CAUSE CORRECTIVE ACTION
ENGINE PLATFORM FAE Engines HM Engines
The sensor could be de- Consult the engine service manual. Disconnect the sensor and plug in a resis-
fective. tive sensor simulator to isolate the fault.
If the control responds to the simulator,
replace the sensor. If control does not re-
spond, go to the next step.

The harness or Base Consult the engine service manual. 1. Remove connector P11 from the
board could be defective. Base board and disconnect the sen-
sor. Check pins P11-11 (H20) and
P11-12 (H20 COM) for a short circuit
as follows:
Check for a short circuit to the
engine block ground (more than
200k is ohms OK).
Check for a short circuit from pin
to pin (more than 200k ohms is
OK).
Repair or replace as necessary.
2. Measure the resistance of the coolant
sensor and reconnect the harness to
the sensor. Remove connector P11
from the Base board and check re-
sistance between pins P11-11 (H20)
and P11-12 (H20 COM).
If resistance is not the same, the
harness is defective and must be
replaced.
If resistance is the same, the
Base board is defective and
must be replaced.

TABLE 6-8. CODE 146 PRE-HIGH COOLANT TEMP (WARNING)


WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: The engine coolant temperature has exceeded the warning threshold for pre-high coolant temperature.
Effect: No action is taken by the control.
POSSIBLE CAUSE CORRECTIVE ACTION
Refer to Fault Code 151. Refer to Fault Code 151.

6-16
TABLE 6-9. CODE 146/151 HIGH OR PRE-HIGH COOLANT TEMPERATURE
(WARNING/SHUTDOWN)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: Engine coolant temperature has exceeded the warning threshold for pre-high/high coolant temperature.
Effect: Calibration-dependent. No action is taken by the Control for Fault Code 146. Engine will shut down for
Fault Code 151.
POSSIBLE CAUSE CORRECTIVE ACTION
ENGINE PLATFORM FAE Engines HM Engines
Fault simulation was en- With a PC based service tool, verify that the fault simulation is not enabled for the
abled with a PC based coolant sensor.
service tool.
If you do not have a PC based service tool, remove battery power from the control to
disable fault simulation overrides.
Engine or sensor circuitry Refer to the engine service manual. Check sensor accuracy with a thermocou-
problem. ple or similar temperature probe.
If the coolant temperature reading is
accurate, the engine may be over-
heating. Refer to the engine service
manual.
If the coolant temperature reading is
not accurate, go to the next step.
The sensor could be de- Refer to engine service manual. Disconnect the sensor and connect a
fective. coolant temperature sensor simulator to
the harness.
If the control responds to the simulator,
replace the sensor. If the control does not
respond, go to the next step.
The harness or Base Not applicable. Measure the resistance of the coolant
board could be defective. sensor and reconnect the harness to the
sensor. Remove connector J11 from the
Base board and check resistance be-
tween pins P11-11 (H20) and P11-12
(H20 COM).
If resistance is not the same, the har-
ness is defective and must be re-
placed.
If resistance is the same, the Base
board is defective and must be re-
placed.

6-17
TABLE 6-10. CODE 153, 154, 155, 195, 196, 197, 285, 286, 418, 426, 1845, 1846, 1852, 1992, 2964 ENGINE
FAULTS ANNOUNCED BY THE PCC1302 (EVENT/WARNING/SHUTDOWN)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: The engine controller has sensed a fault condition and is broadcasting the fault message. The PCC1302 is
uniquely announcing the fault code.
Effect: Event, Shutdown, or Warning
POSSIBLE CAUSE CORRECTIVE ACTION
Consult the engine Consult the engine service manual.
service manual.

TABLE 6-11. CODE 234 OVERSPEED (SHUTDOWN)


WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: Engine speed signal indicates an engine speed greater than shutdown threshold.
Effect: Engine will shut down.
POSSIBLE CAUSE CORRECTIVE ACTION
The engine is cold (no Overspeed can occur when starting a very cold engine. Clear the fault and restart the
coolant heaters) genset.
There is a single step Clear the fault and restart the genset.
large block load removal.
A fault simulation was With a PC based service tool, verify that the fault simulation is not enabled for the
enabled with a PC based coolant sensor.
service tool.
If you do not have PC based service tool, remove battery power from the control to
disable fault simulation overrides.
The fault threshold is not Reset the threshold to the highest allowable setting. Determine the required operating
set correctly with the PC range before adjusting the threshold.
based service tool.
Monitor the engine RPM If the RPM is not correct, refer to Fault Code 121 for corrective action.
using a PC based service
tool.
There is a governor fault. 1. Check the fuel shutoff solenoid adjustment.
2. Replace the defective injection pump unit.
The flywheel tooth count For gensets with a magnetic pickup installed, verify that the flywheel tooth count is
is incorrect. correct for the engine type. Refer to Table 3-25 for a list of flywheel teeth require-
ments and Figure 5-19, sheet 1 for information on how to adjust the flywheel tooth
setting using the operator panel.
The mechanical fuel sys- Verify that the fuel stop settings are correct for your application.
tem setup is incorrect.

6-18
TABLE 6-12. CODE 359 FAIL TO START (SHUTDOWN)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: This indicates that the engine failed to start after expiration of the last crank time.
Effect: Engine will not start.
POSSIBLE CAUSE CORRECTIVE ACTION
Restricted fuel supply be-
cause:
1. The fuel level is be- 1. Add fuel if low. Prime the fuel system.
low the pickup tube
in the tank.
2. There is a closed 2. Open any closed shutoff valve in the fuel line supplying the engine.
shutoff valve in the
supply line.
3. The fuel injectors are 3. Refer to the engine service manual.
clogged.
4. There is air in the 4. Bleed air from fuel system. Refer to the engine service manual.
fuel system.
Glow plugs are not heat- The Base board determines at what temperature and duration of time that the glow
ing because: plugs are energized. Using sensed coolant temperature, the glow plugs are energized
at 77_F (25_C) and colder. The glow plugs are energized for up to 15 seconds when
the coolant temperature is 5_F (20.5_C) or colder. The time duration (150 sec-
onds) is linear between 5_F and 77_F.
With the coolant temperature colder than 77_F (25_C):
1. The glow plug(s) is 1. Each glow plug should be warm to the touch if the engine has just been cranking.
defective. First clean and tighten the terminal of any cold glow plug and then replace it if
necessary.
2. Install a harness tool between the Base board P11 connector. Attempt to start the
2. The Base board is engine and check for B+ at P11-6 (RELAY COIL B+) and GND at P11-7 (GLOW
defective. PLUG SOL).
If B+ / GND is not present, the Base board is defective and must be re-
placed.
If B+ / GND is present, go to step 3.
3. The glow plug relay 3. Check for B+ at the glow plug relay. If not present, check for an open circuit.
is defective.
If there is B+ at the glow plug relay, attempt to start and test for B+ at the other end of
the glow plug relay.
If B+ is not present, the glow plug relay is defective and must be replaced.
If B+ is present, check for an open circuit between the glow plug relay con-
tact and the glow plugs.

6-19
TABLE 6-12. CODE 359 FAIL TO START (SHUTDOWN) (CONT.)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: This indicates that the engine failed to start after expiration of the last crank time.
Effect: Engine will not start.
POSSIBLE CAUSE CORRECTIVE ACTION
The fuel solenoid on the Isolate to the fuse, fuel relay, fuel solenoid, or the Base board.
injection pump is not en-
ergized because:
1. The fuse is open. 1. Remove the fuse (if installed) and check continuity. If open, replace the fuse with
one of the same type and amp rating. If the fuse reopens, check wiring continuity
of the fuel solenoid circuit/test fuel solenoid.
Binding in the solenoid linkage can prevent activation of the hold coil circuitry in the
solenoid. Make sure the solenoid shaft moves completely in and out freely. (Applies
to solenoids with both Pull and Hold coils.)
2. The fuel solenoid is 2. Attempt to start the engine and check for B+ at the fuel solenoid coil.
defective.
If B+ is present, the fuel solenoid is defective and must be replaced.
If B+ is not present, go to step 3.
3. The Base board/K8 3. Check wiring continuity/test K8 relay or fuel pilot:
fuel relay is defec-
Remove the lead from FUEL RELAYCOM (fuel pilot). Attempt to start the engine
tive.
and check for B+ at lead COM.
If there is no B+, check for an open circuit between K8-COM and fuse.
If B+ is present, reconnect lead COM to the relay. Remove the lead from the
N/O connection. Attempt to start the engine and check for B+ at the terminal
N/O connection.
If B+ is present, check for an open circuit between the N/O connection and
the fuel solenoid (+).
If B+ is not present, check to make sure the E-stop switches are inactive,
then check for a ground signal at J11-14. If not, the Base board is defective
and must be replaced.

6-20
TABLE 6-12. CODE 359 FAIL TO START (SHUTDOWN) (CONT.)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: This indicates that the engine failed to start after expiration of the last crank time.
Effect: Engine will not start.
POSSIBLE CAUSE CORRECTIVE ACTION
The injection pump ac- Isolate to the harness, governor actuator, or the Base board.
tuator is not energized
1. Display the Governor Duty Cycle menu. Attempt to start and check for duty
due to the harness, gov-
cycle (44% is about average). If the percentage of duty cycle is displayed before a
ernor actuator, governor
shutdown, the harness, actuator governor, or output circuit of the control is defec-
module, or the Base
tive Go to step 2. (Duty cycle displayed indicates the processor is functioning, but
board is defective.
the output circuitry of the Base board could still be defective.) If the duty cycle is
not displayed, the control is defective or is configured incorrectly. Check the con-
figuration.
2. Remove connector P11 from the control and check wiring continuity of the actua-
tor circuit. Check P11 5 (GOVDR+) and P11-4 (GOVDR) to the appropriate
+/ terminals of the governor module and between J1-4 on the governor module
and the actuator. If continuity is OK, go to step c.
3. Disconnect the two leads attached to the injection pump actuator. Measure the
resistance across the two actuator terminals. A reading of 2.3 ohms indicates that
the actuator circuit is OK. (This test only shows that the actuator circuit is not
opened or shorted, but not if there is binding.) Replace the actuator assembly if
an open or short is measured. If the actuator is OK, go to step 4.
4. Remove power from the control for one minute. Put power back on the control
and check for B+ at P11-5. If not present, the control is defective and must be re-
placed. If present, go to step 5.
5. Attempt to start and check for CNTL B+ at terminal lead ACT + of the governor
actuator (use the engine block for metering ground). If not present, check the wir-
ing or SW B+ control function and J1-3 of the governor module.
6. If CNTL B+ is present, attempt to start the engine and check for a GOV PWM
(pulse wide modulated) signal (measure across the terminals of the actuator and
across J1-2 to J1-1 of the governor module). If not present on J1, the control is
defective and must be replaced.
7. If not present on the actuator, governor module is defective and must be replaced.
The engine fuel system is Service according to the engine service manual.
worn or malfunctioning or
it has lost prime (fuel lift
pump, injection pump, in-
jectors, timing).
The engine is worn or is Service according to the engine service manual.
malfunctioning mechani-
cally.

6-21
TABLE 6-13. CODE 427/781 CAN DATALINK LOST (WARNING/SHUTDOWN)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: Indicates that the communication link between the engine controller and genset controller is lost.
Effect: Warning The control issues a warning level fault if the CAN datalink is lost and while there is no engine
speed or no start command.
Shutdown The control issues a shutdown level fault if the CAN datalink is lost while there is a non-zero
engine speed or a start command is active.
POSSIBLE CAUSE CORRECTIVE ACTION
The networking harness 1. Check the datalink between the ECM and the GCS. Check for open or shorts be-
is defective. tween the following:
J11-20 (CANH)
J11-19 (CANL)
J11-17 (CAN Shield)
2. Also check to make sure that there is 60 Ohms resistance between J11-20 and
J11-19. If not, the harness is defective; repair the harness.
The ECM is powered 1. With the control powered, check for the B+ on the positive side of the keyswitch
down. pilot relay coil. Check for GND on the negative side of the keyswitch relay coil.
2. If B+ doesnt exist, the harness is defective. If GND doesnt exist, check for GND
on P11-21 (Keyswitch LS Out). If GND does exist, the harness is defective, repair
harness. If GND doesnt exist, the Base board is defective and must be replaced.

TABLE 6-14. CODE 441 LOW BATTERY (WARNING)


WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: Low voltage has been detected for the battery.
Effect: The controls voltage supply approaches a level at which unpredictable operation may occur.
POSSIBLE CAUSE CORRECTIVE ACTION
Weak or discharged bat- Recharge or replace the battery. Specific gravity for a fully charged battery is approxi-
tery. mately 1.260 at 80_F (27_C).
Low electrolyte level in Replenish electrolyte and recharge the battery.
the battery.
Battery connections are Clean and tighten or replace the battery cable connectors and cables at the battery
loose or dirty. and the genset.
Insufficient battery charg- Adjust the charge rate of the AC powered battery charging circuit, according to
ing voltage. manufactures instructions.
Engine DC alternator Replace the engine DC alternator if the normal battery charging voltage (12 to 14
could be defective. VDC for 12VDC system, 24 to 27 VDC for 24VDC system) is not obtained.

6-22
TABLE 6-14. CODE 441 LOW BATTERY (WARNING) (CONT.)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: Low voltage has been detected for the battery.
Effect: The controls voltage supply approaches a level at which unpredictable operation may occur.
POSSIBLE CAUSE CORRECTIVE ACTION
If the batteries are OK, Remove connector P11 from the Base board and check battery voltage at
the problem may be with P20-9,10,20,21 (B+) to P20-10 2,4,7,12(GND).
the harness or the Base
If the voltage at P11 is not the same as the battery voltage, the harness is defec-
board.
tive and must be replaced.
If the voltage at P11 is OK, the Base board is defective and must be replaced.
Fault threshold could be Check the fault threshold against the requirement of the application.
incorrect.

TABLE 6-15. CODE 442 HIGH BATTERY VOLTAGE (WARNING)


WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: High voltage has been detected for the battery.
Effect: Control damage will occur.
POSSIBLE CAUSE CORRECTIVE ACTION
Excessive battery charg- Adjust the charge rate of the AC powered battery charging circuit according to the
ing voltage. manufacturers instructions.
Engine DC alternator Replace the engine DC alternator if the normal battery charging voltage (12 to 14
could be defective. VDC) is not obtained.
Fault threshold could be Check the fault threshold against the requirement of the application.
incorrect.

TABLE 6-16. CODE 1311, 1312, 1317, 1318 CONFIGURABLE INPUT (WARNING/SHUTDOWN)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: The nature of the fault is an optional configurable selection.
Effect: Shutdown.
POSSIBLE CAUSE CORRECTIVE ACTION
If there is no actual fault, If the Fault Input Active State select is set to active close, check to see if GND is at
the problem may be an the fault input terminal. If GND is at the fault input terminal, check the external wiring.
external wiring problem.
If the Fault Input Active State select is set to active open, check to see if GND is not
at the fault input terminal. If GND is not at the fault input terminal, check the external
wiring.

6-23
TABLE 6-17. CODE 1426 GENERIC ENGINE FAULT (WARNING)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: The PCC1302 has received a fault code from the engine control module that it doesnt uniquely recognize.
Effect: Warning.
POSSIBLE CAUSE CORRECTIVE ACTION
The engine controller has Use an engine service tool (Insite or InPower) to view the active fault messages being
broadcasted a fault that sent by the engine controller. Consult the engine service manual for a Fault Code
the PCC1302 control mapping and a procedure to cure the problem.
doesnt recognize.
TABLE 6-18. CODE 1443 DEAD BATTERY
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: Indicates during cranking battery voltage has dropped below operating voltage of control resetting the con-
trol for three consecutive times.
Effect: Shutdown.
POSSIBLE CAUSE CORRECTIVE ACTION
Weak or discharged bat- Measure the voltage of battery with voltmeter. Battery voltage should be 12VDC or
tery. greater for 12 VDC system and 24VDC or greater for 24VDC system.
If battery voltage is low, check the electrolyte level.
Replenish electrolyte level if low and recharge the battery
( specific gravity of fully charged lead acid battery is approximately 1.26 at 80 F ( 27
C).
If battery cannot hold adequate voltage, replace battery.
Battery connections are Clean and tighten battery terminals and battery cable connector.
loose or dirty.
If battery cable connectors are cracked or worn out then replace.
Insufficient battery charg- Ensure external battery charger is charging the battery at an acceptable rate. Adjust
ing voltage. the rate if the rate is below the recommendation of the manufacturer.
If battery is located at a far distance from the battery charger, ensure that adequate
wire gauge is used to compensate the voltage drop.
Faulty engine DC alter- Replace engine DC alternator if normal battery charging voltage (12 to 14 VDC for
nator. 12VDC system , 24 to 27 VDC for 24VDC system) is not obtained.
Faulty Harness. Measure the battery voltage at battery terminals when genset is cranking. Then mea-
sure battery voltage at base board input while genset is cranking ( at J209, J2010,
J2020,J2021 for B+ve and J202, J204, J207, J2012 for Bve).
If voltage at battery terminals and control is not the same, check harness and replace
if necessary.

6-24
TABLE 6-19. CODE 1435 LOW COOLANT TEMPERATURE (WARNING)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: The engine coolant temperature has dropped below the warning threshold for low coolant temperature.
Effect: No action is taken by the control. The engine may not start because of a slow cranking speed.
POSSIBLE CAUSE CORRECTIVE ACTION
ENGINE PLATFORM FAE Engines HM Engines
A fault simulation was With the PC based service tool, verify that the fault simulation is not enabled for the
enabled with a PC based coolant sensor.
service.
If you do not have a based service tool, remove battery power from the control to dis-
able the fault simulation overrides.
The fault threshold was Reset the threshold to the lowest allowable setting. Determine the required operating
not set correctly with a range before adjusting the threshold.
PC based service tool.
The engine coolant heat- The coolant heater is not operating because:
er could be defective. The coolant heater is not connected to power. Check for a blown fuse, or discon-
(Radiant heat should be nected the heater cord and correct as required.
felt when your hand is There is a low coolant level. Look for possible coolant leakage points and repair
held close to the outlet as required.
hose.)
There is a defective heater element/thermostat. With the coolant heater removed
from the engine and power disconnected, flush with cold tap water for two min-
utes to close the internal heater thermostat (opens at 100_F and closes at 80_F).
Check resistance across the input power leads:
a. Open replace the coolant heater.
b. Closed coolant heater OK (coil resistance of 10 to 60 ohms)
The sensor connections Inspect the sensor and engine harness connector pins. Repair or replace as neces-
could be defective. sary.
The sensor could be de- Disconnect the sensor and plug in a resistive sensor simulator to isolate the fault.
fective.
If the control responds to the simulator, replace the sensor. If control does not re-
spond, the harness or Base board are defective and must be replaced.

6-25
TABLE 6-19. CODE 1435 LOW COOLANT TEMPERATURE (WARNING) (CONT.)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: The engine coolant temperature has dropped below the warning threshold for low coolant temperature.
Effect: No action is taken by the control. The engine may not start because of a slow cranking speed.
POSSIBLE CAUSE CORRECTIVE ACTION
ENGINE PLATFORM FAE Engines HM Engines
The harness or Base Measure the resistance of the coolant temperature sensor and reconnect the harness
board could be defective. to the sensor. Remove connector P11 from the Base board and check resistance be-
tween pins P11-11 (H20) and P11-12 (H20 COM).
If resistance is not the same, the harness is defective and must be replaced.
If resistance is the same, the Base board is defective and must be replaced.

TABLE 6-20. CODE 1438 FAIL TO CRANK (SHUTDOWN)


WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: This indicates that the engine failed to crank after the control received a start signal.
Effect: Engine will not start.
POSSIBLE CAUSE CORRECTIVE ACTION
ENGINE PLATFORM FAE Engines HM Engines
1. The starter is defec- Refer to the engine service manual.
tive. Reset the control. Attempt to start and test for B+ at the starter. If there is B+ at the
starter, the starter could be defective. Test the starter (see the engine service manual)
and, if necessary, replace the starter. If B+ is not present at the starter, go to the next
step.
2. The starter relay is Check wiring continuity/test starter relay.
defective.
Remove the lead from the starter relayCOM and check for B+ at the lead COM (di-
rectly connected to battery B+).
If there is no B+, check for an open circuit between starter relayCOM and the
battery B+.
If B+ is present, reconnect the lead COM to the starter relay. Remove the lead
from the starter relayN/O. Attempt to start and check for B+ at the terminal start-
er relayN/O.
If B+ is present, check for an open circuit between starter relayN/O and the SW
terminal of the starter.
If B+ is not present, the Base board/starter relay is defective.
3. Either the Emergen- With the Emergency Stop push button not activated, remove the configurable leads
cy Stop switch or the from TB1-15 and TB1-16 and check for continuity between these two leads. If the cir-
wiring is defective. cuit is open, isolate to the Emergency Stop switch and wiring. With the Local Emer-
gency Stop push button not activated, remove P25 from the Base board. Check for
continuity between J25-2 and J25-6. If there is continuity, go to the next step.
4. The MPU/circuit or Refer to the engine service manual. Refer to the Fault Code 121 instructions.
Base board is defec-
tive.

6-26
TABLE 6-21. CODE 1442 WEAK BATTERY (WARNING)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: Low voltage has been detected for the battery.
Effect: The controls voltage supply is approaching a level at which unpredictable operation may occur.
POSSIBLE CAUSE CORRECTIVE ACTION
Refer to Fault Code 441. Refer to Fault Code 441.

TABLE 6-22. CODE 1446 HIGH AC VOLTAGE (SHUTDOWN)


WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: One or more of the phase voltages has exceeded 130% of nominal for 1 seconds, or has exceeded the
High AC Voltage Threshold for the High AC Voltage Delay seconds.
Effect: Engine will shut down.
POSSIBLE CAUSE CORRECTIVE ACTION
Fault simulation was en- With a PC based service tool, verify that the related fault simulation is not enabled.
abled with a PC based
If you do not have a PC based service tool, remove battery power from the control to
service tool.
disable the fault simulation overrides.
Single step large block Clear the fault and restart the genset.
load removal.
Fault threshold is not set Reset the threshold to the highest allowable setting. Determine the required operating
correctly with the PC range before adjusting the threshold.
based service tool.
The Base board or gen- Refer to the Generator/Base Board Isolation Procedure in the Service Manual to de-
erator is defective. termine if the Base board is causing the high AC voltage shutdown fault.
The voltage sense con- Refer to the Generator/Base Board Isolation Procedure in the generator Service
nections/set up could be Manual to determine if the Base board is causing the high AC voltage shutdown fault.
incorrect.

TABLE 6-23. CODE 3539, 3541,3542, 5669 ENGINE FAULTS ANNOUNCED BY PCC1302
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: The engine controller has sensed a fault condition and is broadcasting the fault message. The PCC1302 is
uniquely announcing the fault code.
Effect: Event,Shutdown,Warning.
POSSIBLE CAUSE CORRECTIVE ACTION
Consult Engine Service Consult Engine Service Manual.
Manual.

6-27
TABLE 6-24. CODE 1447 LOW AC VOLTAGE (SHUTDOWN)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: One or more of the phase voltages has dropped below the Low AC Voltage Threshold for Low AC Voltage
Delay seconds.
Effect: Engine will shut down.
POSSIBLE CAUSE CORRECTIVE ACTION
A fault simulation was With a PC based service tool, verify that the related fault simulation is not enabled.
enabled with a PC based
If you do not have a PC based service tool, remove battery power from the control to
service tool.
disable fault simulation overrides.
The fault threshold is not Reset the threshold to the lowest allowable setting. Determine the required operating
set correctly with a PC range before adjusting the threshold.
based service tool.
There is an overload. Check the load and correct any overload. Check operation by disconnecting the load
and restarting the generator set.
Improper connections Reconnect according to the appropriate reconnection diagram.
have been made at the
generator output termi-
nals.
The voltage sense or set- Verify that excitation inputs P18-1 and P18-2 are connected to the correct generator
up wiring connection outputs.
could be incorrect.
The rotating rectifier as- Check each diode. See the genset service manual
sembly (diodes CR1
through CR6) is faulty.
There is a loose connec- Repair connections (P18) or replace the Base board if necessary.
tor or the Base board is
defective.
The voltage sense con- See Section 7 for proper connections.
nections/setup could be
incorrect.

TABLE 6-25. CODE 1448 UNDER FREQUENCY (SHUTDOWN)


WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: Generator AC output frequency is low.
Effect: Generator set will shut down.
POSSIBLE CAUSE CORRECTIVE ACTION
The fault threshold is not Reset the threshold to the lowest allowable setting. Determine the required operating
set correctly with PC range before adjusting the threshold.
based service tool.
There is an overload. Check the load and correct any overload. Check operation by disconnecting the load
and restarting the generator set.
There is a fuel or air de- Refer to the engine service manual.
livery problem

6-28
TABLE 6-25. CODE 1448 UNDER FREQUENCY (SHUTDOWN) (CONT.)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: Generator AC output frequency is low.
Effect: Generator set will shut down.
POSSIBLE CAUSE CORRECTIVE ACTION
There is a governor fault Check the fuel shutoff solenoid adjustment.
There is a loose connec- Repair connections (P22/P18) or replace the Base board if necessary.
tor or the Base board is
defective

TABLE 6-26. CODE 1449 OVER FREQUENCY (SHUTDOWN)


WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: Generator AC output frequency is high.
Effect: Generator set will shut down.
POSSIBLE CAUSE CORRECTIVE ACTION
The fault threshold is not Reset the threshold to the highest allowable setting. Determine the required operating
set correctly with PC range before adjusting the threshold.
based service tool.
There is a fuel or air de- Refer to the engine service manual.
livery problem.
There us a loose connec- Repair connections (P22/P18) or replace the Base board if necessary.
tor or the Base board is
defective.

TABLE 6-27. CODE 1471/1472 HIGH AC CURRENT (SHUTDOWN/WARNING)


WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: This indicates that the indicated generator output current has exceeded at least110% of rated current.
Effect: No action is taken by the control for Fault Code 1472. Engine will shut down for Fault Code 147.
POSSIBLE CAUSE CORRECTIVE ACTION
1. Short or Overload Check the load and load cables. Repair if necessary. Check operation by disconnect-
ing the load and restarting the generator set.
2. Incorrect CTs, CT Check CTs and CT connections. Correct if necessary. Refer to Current Transformer
connections, or CT Setup on page 3-4.
setup.

6-29
TABLE 6-27. CODE 1471/1472 HIGH AC CURRENT (SHUTDOWN/WARNING) (CONT.)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: This indicates that the indicated generator output current has exceeded at least110% of rated current.
Effect: No action is taken by the control for Fault Code 1472. Engine will shut down for Fault Code 147.
POSSIBLE CAUSE CORRECTIVE ACTION
1. The problem may be Remove connector P12 from the Base board. Check continuity from P12 to the CTs.
the Base board or
P12-1 (CT1) to P12-4 (CT1-COM)
harness connections.
P12-2 (CT2) to P12-5 (CT2-COM)
P12-3 (CT3) to P12-6 (CT3-COM)
Repair connections.
2. There may be an in- Check the rating setup in the control. Correct if necessary.
correct rating setup.
TABLE 6-28. CODE 1689 CLOCK NOT SET
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: Exercise Scheduler function is enabled and real time clock (RTC) is not set.
Effect: Warning. Exercise function will not work.
POSSIBLE CAUSE CORRECTIVE ACTION
Battery power recycled If exercise scheduler function is not required, disable the function via HMI211 or ser-
with Exercise Scheduler vice tool.
function enabled.
If exercise scheduler function is required, set and save the real time clock.
RTC not set after enab- Set and save the real time clock.
ling exercise function.

TABLE 6-29. CODE 1944 ANNUNCIATOR OUTPUT CONFIGURATION ERROR (WARNING)


WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: Indicates that more then one network device is configured to activate one of the Annunciator output relays.
Effect: Warning
POSSIBLE CAUSE CORRECTIVE ACTION
Network configuration is Check setup of the devices on the network against duplicate use of the same Annun-
incorrect. ciator relay output.
There is a defective de- Troubleshoot the network for malfunctioning devices.
vice on the network.

6-30
TABLE 6-30. CODE 2118 LOW FUEL PRESSURE
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: Low pressure sensed for gaseous fuel application.
Effect: Warning ( configurable to shutdown )
POSSIBLE CAUSE CORRECTIVE ACTION
Fuel source level is low Check primary fuel source level.
or exhausted.
If refill is required, stop the genset, and refill.
Fuel Pressure switch is Refer engine manual for pressure switch check. Replace if faulty.
faulty.
TABLE 6-31. CODE 2335 LOSS OF AC SENSE (SHUTDOWN)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: This indicates that the control has loss voltage sensing or it has lost zero cross sensing.
Effect: Generator set will shutdown.
POSSIBLE CAUSE CORRECTIVE ACTION
1. There may be prob- Verify that the load contains no shorts. Using a DMM check for shorts between each
lems with the load. of the J22 pins. It also may be helpful to disconnect all load lines and start the genset.
If the genset runs with no load, that could be load lines are shorted.
Refer to the reconnection drawings in Section 7 as a reference.
2. The wire harness is Remove the AC Sense harness (J22) and check continuity of all wires. Repair the
defective. harness as needed, reset the control, and restart the genset.
Check continuity between the following leads. If resistance is greater than 200 Ohms,
repair the harness.
J22 Pin 4 and VN terminal
J22 Pin 3 and V3 terminal
J22 Pin 2 and V2 terminal
J22 Pin 1 and V1 terminal
Check continuity between the following leads. If resistance is greater than 200 Ohms,
repair the harness.
J17 Pin 1 and Field Coil +.
J17 Pin 2 and Field Coil .
Check continuity between the following leads, if resistance is greater than 200 Ohms,
repair the harness:
J18 Pin 1 and V1 terminal (shunt) or PMG 1 terminal (PMG)
J18 Pin 2 and V2 terminal (shunt) or PMG 2 terminal (PMG)

6-31
TABLE 6-31. CODE 2335 LOSS OF AC SENSE (SHUTDOWN) (CONT.)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: This indicates that the control has loss voltage sensing or it has lost zero cross sensing.
Effect: Generator set will shutdown.
POSSIBLE CAUSE CORRECTIVE ACTION
3. The excitation coil The excitation coil may need to be flashed:
isnt charged.
1.. Remove the Field Coil + and Field Coil leads from the alternator.
2.. Using a 12 VDC power supply, touch the positive supply terminal to the Field Coil
+ and the negative supply terminal to the Field Coil . Remove after brief contact.
Repeat this procedure three times.
3.. Reconnect the Field Coil + and the Field Coil leads to the alternator.
4.. Reset the control, and restart the genset.
5.. If the genset fails to operate correctly, repeat steps 14 with a 24 VDC power sup-
ply.
4. The excitation coil is Remove the Field Coil + and the Field Coil leads from the alternator.
defective.
Check continuity between Field Coil + and Field Coil .
Verify that the reading is within alternator specifications. If so, continue to step 4.
5. Verify the genset set- Verify that the genset is capable of reaching rated speed by manually running the
up. genset. Some potential problems could be: clogged fuel filter, incorrect fuel stop posi-
tion, malfunctioning fuel actuators, etc. If the genset is not capable of reaching rated
speed: correct the problem, reset the control, and restart the genset.
6. The control board is Replace the control board module.
defective.

6-32
TABLE 6-32. CODE 2545 KEYSWITCH RESET REQUIRED (SHUTDOWN)
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: After sensing a CAN datalink failed condition (Fault Code 781), the PCC1302 has tried unsuccessfully to
restore communications by toggling power to the ECM.
Effect: Shutdown.
POSSIBLE CAUSE CORRECTIVE ACTION
The networking harness 1. Check the datalink between the ECM and the GCS. Check for open or shorts be-
is defective. tween the following:
J11-20 (CANH)
J11-19 (CANL)
J11-17 (CAN Shield)
2. Also check to make sure that there is 60 ohms resistance between J11-20 and
J11-19. If not, the harness is defective; repair the harness.
The ECM is powered With the control powered, check for B+ on the positive side of the keyswitch pilot relay
down. coil. Check for GND on the negative side of the keyswitch relay coil.
If B+ doesnt exist, the harness is defective. If GND doesnt exist, check for GND on
P11-21 (Keyswitch LS Out). If GND does exist, the harness is defective; repair the
harness. If GND doesnt exist, the Base board is defective and must be replaced.
The keyswitch minimum This time delay sets how long the control waits for the ECM to come online during a
on-time is set too short. power cycle before it determines that the datalink is down and does another power
cycle.
Using InPower, increase the keyswitch minimum on-time trim to the highest possible
value. Reset the fault.
the keyswitch reset time This time delay sets how long it takes for the keyswitch circuits to turn off.
is set too short.
Using InPower, increase the keyswitch reset time delay to the highest possible value.
Reset the fault.
The number of CAN This sets how many times the control power cycles the ECM before it declares Fault
datalink retries is set too Code 2545.
low.
Use InPower to increase this number to the highest possible setting.

TABLE 6-33. CODE 2972 OVER EXCITATION (SHUTDOWN)


WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: The control has sensed an over-excitation caused by an AVR duty cycle greater then 46% (60 Hz) for 8
seconds, or 55% (50 Hz) for 8 seconds.
Effect: Shutdown.
POSSIBLE CAUSE CORRECTIVE ACTION
The load is too large Check to make sure load is with genset capabilities.
The load is faulty. Check for shorts in the load.
The field winding / har- 1. Check for shorts or opens between the two field coils (J18-1 and J18-2) leads. If
ness may be faulty resistance is less then 20 Ohm or greater then 200 Ohms, the field winding or
field winding harness may be defective.
2. Check both 10 amp fuses on J17-1 and J17-2.

6-33
TABLE 6-34. CODE 5134 UNKNOWN SHUTDOWN AT IDLE
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: Genset has shutdown with unknown fault before reaching rated conditions ( for engines with ECM only).
Effect: Shutdown.
POSSIBLE CAUSE CORRECTIVE ACTION
Genset failed to reach Check engine service manual.
rated conditions and
shutdown because of un-
known reasons.

TABLE 6-35. CODE 5186 GENERATOR SET FAILED TO CLOSE


WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: Transfer switch has failed to close on generator side.
Effect: Shutdown.
POSSIBLE CAUSE CORRECTIVE ACTION
Mechanical failure of Check the transfer switch manual.
transfer switch.
Transfer switch transi- Check for loose connection of the feedback wire connected to TB114 from auxiliary
tioned to genset side, but contact of transfer switch. Tighten the same.
feedback is lost.
Faulty auxiliary contact. Check and replace the auxiliary contact of transfer switch.

TABLE 6-36. CODE 5187 UTILITY FAILED TO CLOSE


WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: Transfer switch has failed to close on utility side.
Effect: Warning.
POSSIBLE CAUSE CORRECTIVE ACTION
Mechanical failure of Check the transfer switch manual.
transfer switch.
Transfer switch transi- Check for loose connection of the feedback wires connected to TB112 and TB114
tioned to utility side, but from auxiliary contact of transfer switch. Tighten the same.
feedback is lost.
Faulty auxiliary contacts. Check and replace the auxiliary contact of transfer switch.

6-34
TABLE 6-37. CODE 5365 ON SECONDARY SOURCE
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: Genset is running on secondary fuel source in dual fuel application.
Effect: Warning.
POSSIBLE CAUSE CORRECTIVE ACTION
Primary fuel source level Check primary fuel source level.
is low or exhausted and
If refill is required, stop the genset, and refill.
genset is transitioned to
run on secondary fuel
source.
Fuel Pressure switch is Refer engine manual for pressure switch check. Replace if faulty.
faulty.
TABLE 6-38. CODE 5188 TRANSFER SWITCH UNKNOWN POSITION
WARNING Hazards present in troubleshooting can cause equipment damage, severe person-
al injury or death. Only trained and experienced service personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform service procedures. Read Important Safety In-
structions pages and observe all instructions and precautions in this manual.
Reason: Transfer switch position is not known.
Effect: Warning.
POSSIBLE CAUSE CORRECTIVE ACTION
Mechanical failure of Check the transfer switch manual.
transfer switch. Feed-
back indicating as, it is
neither at utility side nor
at genset side OR feed-
back is indicating it is at
genset as well as at utility
side at the same time.
Transfer switch is either Check for loose connection of the feedback wire connected to TB112 from auxiliary
at genset side or utility contact of transfer switch. Tighten the same.
side, but respective feed-
Faulty auxiliary contact. Check and replace the auxiliary contact of transfer switch.
back is lost or both side
feedbacks are available.

6-35
THIS PAGE LEFT INTENTIONALLY BLANK

6-36
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix


1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Connector Seal Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Kit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Additional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
1302 Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Current Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
1302 Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Control Run/Off/Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Operator Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Control Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Control Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Control Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Protection and Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Genset Protective Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Engine Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Alternator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Running Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Parade Rest Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Environmental Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
1302 Main Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
1302 Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Control Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Guidelines for Current Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Current Transformer Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Example of CT Sizing Two Lead CT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Example of CT Sizing Three Lead CT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Current Transformer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Two Lead CT Setup Example: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
In PCC1302 Control, Voltage Calibration procedure is divided into three processes as de-
scribed below: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Procedure of calibrating the Alternator Voltages is as follows: . . . . . . . . . . . . 3-5
Safety Precautions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Three Lead CT Setup Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Battery Charging Alternator Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Denso Type Charging Alternators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Bosch Type Charging Alternators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Alternator Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Series Star . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Series Delta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Parallel Star . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Double Delta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Single Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Guidelines for Engine Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Coolant Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Oil Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Lube Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Control Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Electronic Governor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Setup, Trims, and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Alternator Control Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
AVR Enable/Disable Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Digital Output Voltage Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Torque-Matched Volts/Hz Overload Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Battleshort Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Genset Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
V/Hz Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Governor Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Engine Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Alternator Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Setup for Gain Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Gain Tuning Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Controller Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
1302 Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Remote Start Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Remote Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Local Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
12/24V Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Cycle Cranking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Spark Ignition Power/Glow Plug Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Glow Plug Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Preheat Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Total Glow Processing: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Glow Plug Output Logic: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Start and Stop Time Delays (Cool Down) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Electronic Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Engine Speed Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Speed Governor Algorithm and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
real time clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
exercise scheduler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
The following are the set of rules for exercise scheduler . . . . . . . . . . . . . . . . . 3-53
ATS Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Dual Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Battle Short Mode Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Installations With an Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Installations Without an Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Battle Short Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Installations with an Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Installations without an Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
4. Operator Panel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Local Status Output Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Manual Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Emergency Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Installations with an Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Installations with a Manual Run/Off/Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Graphical Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Display Text / Symbolic Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Display Menu Selection Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Previous Main Menu Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Off Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Not In Auto Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Shutdown Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Warning Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Remote Start Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Auto Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Manual Run Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Operator Panel System Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Communication Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Event Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Fault Reset / Acknowledgement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Fault/Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Adjusting Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Saving Your Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Operator Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Engine Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Alternator Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Alternator Line-to-Line Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Alternator Line-to-Neutral Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Alternator Single Phase Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Alternator Amperage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Selecting Auto, Manual Run, and Off Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Entering the Mode Change Access Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Selecting Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Selecting Manual Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Aborting the Transition to Auto or Manual Run Mode . . . . . . . . . . . . . . . . . . . . 4-23
Selecting Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Network Status Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
History / About Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
History Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
About Genset Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
About Control Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
About Display Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Fault History Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Screen Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Adjusting Values/Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Screen Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
5. 1302 Control Panel Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Genset Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Viewing Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Viewing and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Setup Password Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Adjusting Values/Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Genset Service Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Genset Menu, Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Genset Menu, Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Start/Stop Delay Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Cycle Crank Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Battle Short Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
AVR Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Electronic Governor Menu, Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Electronic Governor Menu, Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Genset Number Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Display Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Volts and Hertz Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Automatic Voltage Regulator Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Volts/Hz Rolloff Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Regulator Gains Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Electronic Governor Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Governor Crank Fuel Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Electronic Governor Regulator Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Electronic Governor Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Electronic Governor Enable Speed Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Customer I/O Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Fault Input Function Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Customer Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Fault Input Active State Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Customer Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Metering Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Meter Calib Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Freq. Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Metering Voltage Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Metering Current Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Annunciator Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Annunciator Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Annunciator Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
ModBus Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
ModBus Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
ModBus Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Genset Setup Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Viewing Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Viewing and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Genset Setup Password Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Adjusting Values/Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Genset Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Genset Menu 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Genset Menu 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Application Rating Select Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Standby kVA Rating Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Prime kVA Rating Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Battery Select Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Battery Thresholds Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Battery Delay Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Oil Pressure Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Voltage Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
High AC Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Low AC Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Overfrequency Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Underfrequency Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Alternator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Current Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
High AC Current Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Engine Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Engine Protection Overspeed Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Engine Protection Speed/Frequency Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Low Oil Pressure Warning Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Low Oil Pressure Shutdown Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
High Coolant Temperature Warning Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
High Coolant Temperature Shutdown Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Engine Protection Low Coolant Temperature and Battery Charger Menus . . 5-53
6. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
PC Based Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Network Applications and Configurable Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Reading Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Reading Fault Codes Using Optional Operator Panel . . . . . . . . . . . . . . . . . . . . 6-2
Reading Fault Codes Using the Control Switch Indicator . . . . . . . . . . . . . . . . . 6-2
Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Voltage/Continuity Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
7. Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Appendix A. 1302
Menu System Maps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Appendix B. Index . .
B-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
7. Wiring Diagrams
GENERAL S Page 7-3, 1302 Control Wiring Diagram
This section consists of the schematic and connec-
tion wiring diagrams referenced in the text. The fol-
lowing drawings are included.

7-1
THIS PAGE INTENTIONALLY LEFT BLANK

7-2
J29 6 Run (Wakeup) J2510

HMI2xx J29 4 Auto


(Configurable Wakeup)
J2511 PCC 1302 OEM Genset
or HMI3xx ECM Engine Connection Configurable Input
#3, Coolant Level
Input
Return
J20 17
J20 5
Switch
Display (Wakeup)
J20 1

J29 1 PCC Net A (+) J254 Chassis Ground


Part numbers J29 2 PCC Net B () J253 Configurable Input Input J20 18 Locate near
HMI 220: J29 3 System Wakeup J255 #4, Fuel Level Switch Return J20 6 mounting screw
J20 9
03006314 HMI Fused B+ and (Wakeup) chassis.
HMI 320: Customer Fused B+ J20 10
03006315 Switches OEM
share a common 4.5A J20 20
J28 Mate: Part numbers Part numbers connected OR
J28 1 HMI Fuse B+ J2512 fuse. Fused B+ 20 Amp
03232091 J25 Mate: 03232445 J20 Mate: 03232446 Terminal blocks for J20 21
J28 2 B+ Return J258 HMI Fused B+ is
J29 Mate: Sockets: 03232466 Sockets: 03232466 customer connections
assumed to consume
03232456 Use Shielded Twisted Pair for PCC Net no more than 1.5A J20 2 B+ Return
Sockets: 03232466 Only terminate shield on one end
J25 Display J20 Genset J20 4
J20 7 +
Terminal Terminal
OR Block J20 12
Block Battery
Manual (Wakeup) J2510 Fused B+ J20 J11, J25 Fused B+ Battery
J1 6 Harness Harness
Charging
J2511
J1 7
Auto (Configurable Wakeup)
These signals Alternator Switched
Local go to the Remote Estop Basic Basic Estop B+ Power (IC Regulator B+
PCC Net A (+) J254 Type/
HMI211 J1 1
J1 2
PCC Net B () J253
display but
don t go
PB (B) Customer Customer
Kubota) IC
Regulator
Display J1 4 System Wakeup J255 through the
PCC controller. PCC1302 Baseboard
Power
Battery Charger Estop B+
Pilot Relay
Lamp
Alternator J2022 Power FSO
Part numbers Failed
These signals Flash/ Failed J20 14 LS Out Control
HMI Fuse B+ J2512 Output
HMI211: J1 3 Part numbers go to the
03006014 J1 5 B+ Return J258 PCC 1302: 0327161701 genset but Estop B+
don t go OR Power Starter
through the
J20 15 LS Out Control
PCC controller.
Battery
Charging Estop B+
HMI 114 Alternator Switched
B+
Power Switched B+
(NonIC Regulator
Bargraph J1 3
J1 4
PCC Net A (+)
PCC Net B ()
J254
J253
Type/
Bosch) J20 11
J20 3 LS Out (Run) Control

J1 5 System Wakeup J255

Part numbers Battery Charger


HMI 114: Field Alternator J20 22
0300???? Part numbers Flash Flash/ Failed
J1 & J6 Mate: J12 Mate: 03231932 Relay B+ internally
03232011 J6 1 HMI Fuse B+ J2512 B.C. Alt. Flash
Sockets: 03231200 fused at 1.85A
Sockets: 03232466 internally fused at
J6 2 B+ Return J258
1.5A
J12 Genset Current Field Winding

Input (Wakeup on open) J25 2


+
Driver
Local A Return J25 6
These signals J22 Genset Voltage Rating:

Estop
go to the
engine but Part numbers
Alternator 4 Amps

Fused B+ don t go J11 Mate: 03232161 Part numbers Peak: 6


through the Sockets: 03232466
PB B Remote Estop PB (B) J22 Mate: 0323222603 Amps
PCC controller.

J11 Engine
Terminal Block
Terminal L1 L2 L3 LN
Block J12 1
Fused B+ J20 J12 4
Harness
J12 2
Fused B+ J12 5 5A
CT s,
J12 3
Pilot Relay Don t connect J12 6
Estop B+ N in Delta
Power configuration
Keyswitch
Keyswitch
J11 21 LS Out Control
(FSO ECM Use L1/L2/N
J22 1
optionally)
(PGI for 1 phase
J22 2
Compliant) applications J22 3
J11 20 J1939 (+) J1939 (+) J22 4

120 120 ohm terminated


Ohm
J11 19 J1939 ()
J1939 ()
J11 17 J1939 (Shield)
Use alternator center taps LL 600 Volt Max
Only terminate shield or a transformer
on one end Some ECM s integrate if LL voltage > 240 VAC
the FSO with the
Keyswitch operation. Shunt Applications
Use a dedicated FSO if
application s ECM does OR
not provide FSO J18 AVR Power J18 1
10 Amp
operation.
J18 2 PMG Applications
Part numbers P2
J18 Mate: 03232444
Sockets: 03231200 J18 3
PMG
Part numbers (optional)
J17 Mate: 03232098 P4
Sockets: 03231200 P3

J17 AVR Control J17 2 No. 630-3270 Sh 1 of 4


J17 1
Rev. Sys: ProE
Modified

FIGURE 7-1. 1302 CONTROL WIRING DIAGRAM


(SHEET 1 OF 4)

7-3
J29 6 Run (Wakeup) J2510

HMI2xx J29 4 Auto


(Configurable Wakeup)
J2511
PCC 1302 OEM Genset
or HMI3xx Hydromechanical Engine
Configurable Input
#3, Coolant Level
Input J20 17

Display
Return J20 5
Switch

Part numbers J29 1 PCC Net A (+) J254


Connection (Wakeup)
J20 1

Chassis Ground
HMI 220: J29 2 PCC Net B () J253 Input J20 18 Locate near
03006314 Configurable Input
J29 3 System Wakeup J255 mounting screw
HMI 320: #4, Fuel Level Switch Return J20 6 J20 9
HMI Fused B+ and (Wakeup) chassis.
03006315 J20 10
Customer Fused B+
J28 Mate: Switches OEM
HMI Fuse B+ share a common 4.5A J20 20
03232091 J28 1 J2512 Part numbers Part numbers connected OR
fuse. Fused B+ 20 Amp
J29 Mate: J28 2 B+ Return J258 J25 Mate: 03232445 J20 Mate: 03232446 Terminal blocks for J20 21
HMI Fused B+ is
03232456 Sockets: 03232466 Sockets: 03232466 customer connections
Use Shielded Twisted Pair for PCC Net assumed to consume
Sockets: 03232466
Only terminate shield on one end no more than 1.5A J20 2 B+ Return

J25 Display J20 Genset J20 4

OR J20 7 +
Terminal Terminal
Manual (Wakeup) J2510 Block J20 12
J1 6
Block
J11, J25 Fused B+
Battery
Auto (Configurable Wakeup) J2511 Fused B+ J20 Battery
J1 7 Harness Charging
Local These signals
Harness
Alternator Switched
PCC Net A (+) J254
HMI211 J1 1
J1 2
PCC Net B () J253
go to the
display but
Remote Estop
PB (B)
Basic
Customer
J11
Harness
B+ Return (IC Regulator
Type/
IC
B+

Display J1 4 System Wakeup J255 don tgo


through the
Basic
Customer
Estop B+ Power
Kubota)
Regulator
Power

Part numbers
PCC controller. PCC1302 Baseboard Lamp Battery Charger Estop B+
Pilot Relay

HMI Fuse B+ J2512 Alternator J2022 Power FSO


HMI211: J1 3 Failed
These signals Flash/ Failed Control
03006014 B+ Return J258 Part numbers Output J20 14 LS Out
J1 5 go to the
PCC 1302: 0327161701
genset but Estop B+
don t go OR Power Starter
through the
J20 15 LS Out Control
PCC controller.
Battery
Charging Estop B+
HMI 112 Alternator
(NonIC Regulator
Switched
B+
Power Switched B+

Bargraph J1 3
J1 4
PCC Net A (+)
PCC Net B ()
J254
J253
Type/
Bosch) J20 11
J20 3 LS Out (Run) Control

J1 5 System Wa keup J255


Relay B+ internally
Part numbers fused at 1.85A
Battery Charger
HMI 112: Field Alternator J20 22
0300605002 Part numbers Flash Flash/ Failed
J1 & J6 Mate: J12 Mate: 03231932
03232011 J6 1 HMI Fuse B+ J2512 B.C. Alt. Flash
Sockets: 03231200
Sockets: 03232466 internally fused at
J6 2 B+ Return J258
1.5A
J12 Genset Current Field Winding

Input (Wakeup on open) J25 2


+
Driver
Local A Return J25 6 These signals J22 Genset Voltage Rating:

Estop
go to the
engine but Part numbers
Alternator 4 Amps

Fused B+ don t go J11 Mate: 03232161 Part numbers Peak: 6


PB B Remote Estop PB (B)
through the
PCC controller.
Sockets: 03232466 J22 Mate: 0323222603 Amps

J11 Engine
+5V J11 1 Terminal Block
Active Oil Sense J11 3 Relay B+ internally Terminal L1 L2 L3 LN
Pressure Sender fused at 1.85A Block J12 1
Return J11 2
Fused B+ J20 J12 4
Pilot Relay Harness
OR J11 6 Relay B+ J12 2 5A
Glow Plug B+ Return J20 J12 5 CT s,
Passive Oil Sense J11 3 J11 7 LS Out Control Harness J12 3
Pressure Sender Return J11 2 J12 6
OR Don tconnect
N in Delta
OR J11 6 Relay B+
Ignition configuration
Input J11 3
Low Oil Pressure Module J22 1
Return J11 2 J11 7 LS Out
Switch Control
Use L1/L2/N J22 2
for 1 phase J22 3
Coolant applications J22 4
Sense J11 11 J11 5 Governor PWM + 3 rd Party
Temperature Fuel Actuator
Sensor Return J11 12 J11 4 Governor PWM Module
(Onan Type) (20mA Max)
OR
Mag Use alternator center taps 600 Volt Max
Fused B+ LL
Pickup + J11 9 J11 5 Governor PWM + J1 2 Fuel or a transformer
J11 4 Governor PWM J1 1 J1 4 Act. LS Driver Actuator if LL voltage > 240 VAC
J11 10
(6 Amps Max)
Shield J11
J1 Gov PS

8
Shunt Applications
Use Shielded Twisted Pair for Mag PU
OR
Fused B+ Gov PS Power J1 3 J18 AVR Power J18 1
10 Amp
B+ Return Gov PS Power J1 5
J18 2 PMG Applications
Part numbers P2
J18 Mate: 03232444
J18 3
Sockets: 03231200 PMG
(optional)
AUX 104 Part numbers
J17 Mate: 03232098 P4

GOVERNOR POWER STAGE Sockets: 03231200 P3

Part numbers
Aux 104: 03271507
J17 AVR Control J17 2 No. 630-3270 Sh 2 of 4
J1 Mate: 03232216 : Sockets: 03231200 J17 1
Rev. Sys: ProE
Modified

FIGURE 7-1. 1302 CONTROL WIRING DIAGRAM (SHEET 2 OF 4)

7-4
Remote Start TB110
J1 7
PCC 1302 Customer Connections:
Input #1 Input #2
System Wakeup TB15 5
Input #3 Input #4 Input #5 Input #6 Remote
+/5V Analog Sense J11 1 J11 3 J1 4 PCC Net A (+) TB1 1
Oil
Sense
Current source
J11 5
J10 3
J11

J10 4
7 J11 9
J10 5
J11 11
J10 6
Input Return J11 2 J11 4 HMI211 J1 1
J1 2
PCC Net B () TB1 2 PCC Net Devices
Temperature Part numbers Customer Fused B+ TB1 5
RTD J1 3
Current return J10 9 J10 10 J10 11 J10 12 HMI211: B+ Return TB1 3
Sensor J1 5
Sense return J11 6 J11 8 J11 10 J11 12 03006014

Sense
OR J29 3 System Wakeup TB15 5
Exhaust Stack Current source HMI2xx J29 1 PCC Net A (+) TB1 1
Temperature #1
RTD Current return and J29 2
J28 1
PCC Net B ()
Customer Fused B+
TB1 2
TB1 5
Sensor Sense return
HMI3xx J28 2 B+ Return TB1 3
OR OR
Ambient
Sense
Current source
Gnd must be
Discrete Input (Sense)
Return
Display
Temperature wired in
System Wakeup TB15 5
RTD Current return
Sensor Sense return
Customer
Fused B+ Battery PCC Net A (+)
PCC Net B ()
TB1 1
TB1 2

Sense
OR Gnd must be Discrete Input (Sense) OR Charger Customer Fused B+ TB1 5
wired in Return B+ Return TB1 3
Fuel Level Current source
Sensor
RTD Current return
AND/
Sensor Sense return
OR HMI 112
J15
J13
System Wakeup
PCC Net A (+)
TB15 5
TB1 1
PCC Net must use a daisy chain
topology only PCC1302
Sense
OR
Bargraph J14 PCC Net B () TB1 2
Use Shielded Twisted Pair for PCC Net
Baseboard
Intake Manifold Current source Input #7 Input #8 J61 Customer Fused B+ TB1 5
Part numbers Only terminate shield on one end, to
Temperature J62 B+ Return TB1 3 prevent ground loops
Current return 038V Analog Sense J11 13 J11 15 HMI 112: 0300605002
RTD
Sensor Input Return
Sense return J11 14 J11 16
Use a local, floating (nongrounded)
DC power supply if B+ line has high
Sense
OR
Gnd must be
Discrete Input (Sense) OR HMI 113 J23 PCC Net A (+) TB1 1 resistance (>1 ohm) due to long runs,
05V Analog Input Sense return to prevent brief power outages during
wired in Return
Annunciator J24 PCC Net B ()
TB116 Customer Fused B+
TB1 2
TB1 5
genset starts
Discrete Input (Sense) OR Customer
Gnd must be Part numbers TB115 B+ Return TB1 3
Return Fused B+ w/o enclosure: Refer to the PCCNet Spec Sheet for
wired in
Gnd must be Discrete Input (Sense) OR 300592901 further details on PCCNet
Customer w/ enclosure:
wired in Return
Fused B+ 300592902

Gnd must be Discrete Input (Sense) OR AND TB 1


wired in Return J11 /OR
AND AND AND J10 Aux 101 J1 5 System Wakeup TB15 5

/OR /OR /OR


J4 Remote I/O J1 3 PCC Net A (+) TB1 1
J1 4 PCC Net B () TB1 2
TB 15
J3
Part numbers Customer Fused B+ TB1
J14 1 5
Aux 101:
J14 2 B+ Return TB1 3
03271536
J2 Mounting screw

J5
Chassis Ground

J6
J2 1 Relay NO
Aux 101 J1
J2 2 Relay Com 1 Relay NO
Relay 1 Aux 102
J2 3 Relay NC Output
Maximum J2 1 Relay Com Relay 9
Aux 102
Relay Output
of 2 Aux Relay NC
J1
J3 1 Output
J2 4 Relay NO Ratings:
101 &
J2 5 Relay Com
Aux 101
Relay 2 102s can Aux 102 J1 2 Relay NO
Aux 102
2 A,
30VDC,
Relay NC J2 Relay Com
Remote I/O
J2 6 2
Output Relay 10 250VAC
be used Relay NC
J2
J3 2 Output
J2 7 Relay NO per
Aux 101 Part numbers J1
J2 8 Relay Com genset 3 Relay NO Part numbers
Relay 3 Aux 102: Aux 102
J2 9 Relay NC Output J2 3 Relay Com Aux 101 mates:
03271265 Relay 11
J2 10 Relay NO Aux 101
J3 J3 3 Relay NC Output J1: 0323219204
J14: 0323167802
Aux 101 J1
J2 11 Relay Com Relay Output 4 Relay NO Others: come w/ board
Relay 4 Aux 102
Ratings: J2 Relay Com Aux 102 mates:
J2 12 Relay NC Output 4
Relay 12
30VDC, J1, J2, J3: 0323167808
J3 4 Relay NC Output
250VAC J4: 0323167807
NO: 5A J1 5 Others: come w/ board
Relay NO
J3 1 Relay NO NC: 3A Aux 102
Aux 101 J2 5 Relay Com
J3 2 Relay Com Relay 13
Relay 5 Input J4 1 J3 5 Relay NC Output
J3 3 Relay NC Output Input #9 Return J4 2
J1 6 Relay NO

J4
J3 4 Relay NO Input J4 3 Aux 102
Aux 101 J2 6 Relay Com
J3 5 Relay Com Relay 14
Relay 6 Input #10 Return J4 4 J3 6 Relay NC Output
J3 6 Relay NC Output
Input J4 5 J1 7 Relay NO
J10 Input #11 Return J4 6 J2 7 Relay Com
Aux 102
Relay 15
J4 1 Relay NO Input J4 7
J3 7 Relay NC Output
J10 7 + Aux 101
5VDC Supply #1 J4 2 Relay Com Input #12 Return J4 8
Relay 7 J1 8 Relay NO
J10 9 Return (20 mA max) J4 3 Relay NC Output J2 8 Relay Com
Aux 102
Relay 16
J4 4 Relay NO J3 8 Relay NC Output
J10 8 + Aux 101
5VDC Supply #2 J4 5 Relay Com Relay 8
J10 10 Return (20 mA max) J4 6 Relay NC Output No. 630-3270 Sh 3 of 4
Rev. Sys: ProE
Modified

FIGURE 7-1. 1302 CONTROL WIRING DIAGRAM


(SHEET 3 OF 4)

7-5
CCS WD
PCC 1302 Customer Connections:
06303270 WDCONTROL
(WDCONTROL 1302)
Part numbers
TB 1 Mate: 03232434
FRD24967
TB1 Basic
Terminal
Block
Estop B+ Power J20
Harness
These signals
go to the Local Estop PB J25
(B) Harness
Input (Wakeup on open) TB1 16 TB1 1 PCC Net A (+) RS485 PCC Net customer but
don t go
Remote A Return TB1 15
TB1 2 PCC Net B () RS485
Devices through the
PCC controller.
PCC 1302 Baseboard
TB1 3 PCC Net B Shield
Estop (See Customer
Local Estop PB (B) PCC Net page)
PB B Estop B+ Power
(Remove jumper
if not used) Remote Input TB1 11 TB1 6 Relay NO
Customer Relay Output
Start Return TB1 10 TB1 7 Relay Com Output #1 Ratings:
(Wakeup)
See Application Notes Input TB1 12 3.5 A,
section for high level Customer TB1 8 Relay NO 30VDC,
Estop circuit Input #1 Return TB1 13 Customer
TB1 9 Relay Com Output #2 250VAC
Input TB1 14
Customer
Input #2 Return TB1 15
Ready To
TB1 4 Low Side Driver
Load Output

TB1 5 + Customer fused


Battery Supply
TB1 10 Return (3A max)

Items in dashed lines


represent internal
Battery PCC circuitry.

Part numbers
TB 8 Mate: 0323232503

TB15 Modbus/PC Tool


Part numbers
TB 15 Mate: 0323219204

System Wakeup:
Ground if the PCC
control system is to
PCC Net
always stay awake. Devices
(See Customer
TB15 System Wakeup
5
PCC Net page)

TB15 3 RS485 (+) (+) Modbus


120 120 ohm terminated
Ohm
TB15 4 RS485 ()
()
TB15 1 Shield

Only terminate shield


on one end

OR

PC Tool Harness
PC Tool
Part numbers
PC Tool Harness kit: 05411199
No. 630-3270 Sh 4 of 4
Rev. Sys: ProE
Modified

FIGURE 7-1. 1302 CONTROL WIRING DIAGRAM (SHEET 4 OF 4)

7-6
Appendix A. 1302 Menu System Maps
The illustrations in this section show an overview of vice, Genset Setup, and Genset Service menus.
menu navigation. These illustrations can also be
used to locate a submenu and determine how to ac- The illustrations only show the text versions of the
cess it. menus. In addition, the menus shown in the setup
and service menus reflect what is displayed if the
The first illustration shows the basic Operator Me- appropriate passwords are entered for viewing and
nus. The remaining two illustrations show the Ser- changing the menus.

A-1
OPERATOR MENUS
TEXT VERSION

THREE
PHASE
ONLY

SINGLE
PHASE
ONLY
THREE
PHASE
WYE ONLY

CURRENT
SENSE
AMPERAGE

MANUAL
RUN MODE
SELECTED

AUTO MODE
SELECTED

A-2
GENSET SERVICE MENUS

VIEWING AND
VIEWING ONLY ADJUSTING

GO TO GENSET
OR SETUP AND
SERVICE MENUS
ON PAGE A-4

OR
*

* ONLY ONE OF THE FOUR


AVAILABLE INPUT MENUS
IS SHOWN.

YES NO
OR IF AVR IS
NOT
ENABLED
OR
IF AVR IS
ENABLED
YES NO
OR

A-3
GENSET SETUP AND SERVICE MENUS

OR

GO TO GENSET
SERVICE MENUS
ON PAGE A-3

VIEWING AND
VIEWING ONLY ADJUSTING

OR

12V 24V
OR

OR

THESE MENUS ARE AVAILABLE ONLY


IF ECM CAN FEATURE IS DISABLED

SWITCH SENDER
OR

A-4
Appendix B. Index

GENERAL INFORMATION

A Current Transformers, 3-3


Selection, 3-3
Alternator Setup, 3-4
Adjustments, 3-26 Three Lead, 3-5
AVR Enable/Disable, 3-26 Two Lead, 3-4
Bosch Type, 3-5 Sizing
Connections Three Lead, 3-4
Double Delta, 3-7 Two Lead, 3-3
Parallel Star, 3-6 Cycle Cranking, 3-37
Series Delta, 3-6
Series Star, 3-6
Single Phase, 3-7
E
Denso Type, 3-5 Electronic Governor
Digital Output Voltage Regulation, 3-26 Connections, 3-15
TorqueMatched Volts/Hz Overload Control, 3-26 Module Connections, 3-15
Part Numbers, 3-15
Auto Mode, 2-3, 4-2
Emergency Stop
Local, 3-37
B Remote, 3-37
Battery Selection, 3-37 Emergency Stop Mode, 4-2
Battle Short Engine Speed Sensing, 3-39
Installations with Operator Panel, 3-40 Engine Starting, Automatic, 3-37
Installations without Operator Panel, 3-41
Environment Information, 3-2
Mode, 3-41
Equipment
Battleshort Mode, 3-26 Basic, 2-1
Optional, 2-2
C
Control
F
Inputs, 2-5 Fault, No Message, 6-3
Outputs, 2-5 Fault Code
Control Board 1117 ECM Power Lost, Warning, 4-10
Connections, 3-10 1123 Shutdown After Battleshort, Shutdown, 3-41,
J11 (Engine), 3-12 3-42, 4-10, 6-8
J12 (Genset CT), 3-12 1131 Battle Short Active, Warning, 3-41, 4-10, 6-8
J17 (Field Windings), 3-13 121 Speed Signal Lost, Shutdown, 3-41, 3-42, 4-8,
J18 (Field Power), 3-13 6-6, 6-12
J20 (Genset), 3-13 1246 Generic Engine Fault, Warning, 4-10
J22 (Genset Voltage Sensing), 3-13 1311 and 1312 Configurable Input 1, 2, Warning/
J25 (Display), 3-14 Shutdown, 4-10, 6-8, 6-23
TB1 (Customer), 3-11 1317 and 1318 Configurable Input 3, 4, Warning/
TB15 (Tools Interface), 3-11 Shutdown, 4-11, 6-8, 6-23
Connector Part Numbers, 3-14 135 Oil Pressure Sensor OOR High, Warning, 4-8
Footprint, 3-16 141 Oil Pressure Sensor OOR Low, Warning, 4-8,
General Information, 3-2 6-6, 6-13
1416 Failure to Shutdown, Warning, 3-41, 4-11,
Current Draw 6-9
Parade Rest Mode, 2-7 1417 Failure to Power Down, Shutdown, 4-11
Running Mode, 2-7 142 Oil Pressure Sensor OOR High, Warning, 6-6,
Sleep Mode, 2-7 6-13
B-1
GENERAL INFORMATION
1426 Generic Engine Fault, Warning, 6-24 2542 Voltage Bias OOR, Warning, 4-13
143 PreLow Oil Pressure, Warning, 4-8, 5-48, 2545 Keyswitch Reset Required, Shutdown, 6-31
6-6, 6-13, 6-14 2619, 2621, 2622, 2623, 2624, 2625, 2626, and
1433 Remote Emergency Stop, Shutdown, 3-41, 2628 AUX101 Analog Inputs 18, Diagnostic,
3-42, 4-11, 6-9 4-13
1434 Local Emergency Stop, Shutdown, 3-41, 2628, 2629, 2631, and 2632 AUX101 Digital Inputs
3-42, 4-11, 6-9 14, Diagnostic, 4-14
1435 Low Coolant Temperature, Warning, 4-11, 2676 Alternator Frequency Conflict, Shutdown,
5-52, 6-9, 6-24 4-14, 6-10
1438 Fail to Crank, Shutdown, 4-11, 6-9, 6-25 2677 Fail to Stop, Shutdown, 4-14, 6-11
144 Coolant Sensor OOR Low, Warning, 4-8, 6-6, 2678 Battery Charging Failure, Warning, 4-14, 5-8,
6-15 5-52
1442 Weak Battery, Warning, 4-11, 5-42, 6-9, 6-26 2693 Speed Bias OOR, Warning, 4-14
1443 Dead Battery, Warning, 4-11, 6-24 2694 Alternator RTD Temp OOR, Warning, 4-14
1446 High AC Voltage, Shutdown, 4-11, 5-44, 6-9, 2696 Alternator RTD Temp High, Shutdown, 4-14
6-26 2729 I/O Module Lost, Warning, 4-15
1447 Low AC Voltage, Shutdown, 4-11, 5-44, 6-10, 2731 I/O Module Lost, Warning, 4-15
6-27 285, and 286 Engine Fault, Event, Warning, or
1448 Under Frequency, Shutdown, 4-11, 5-44, Shutdown, 4-9, 6-18
6-10, 6-27 2897 Factory Block Corrupt, Shutdown, 4-15
1449 Over Frequency, Shutdown, 4-11, 5-44, 6-10, 2898 Periodic Fault Corrupt, Warning, 4-15
6-28 2899 User Block Corrupt, Shutdown, 4-15
145 Coolant Sensor OOR High, Warning, 4-8, 6-6, 2911 Trim Block Corrupt, Shutdown, 4-15
6-15 2964 Engine Fault, Event, Warning, or Shutdown,
146 PreHigh Coolant Temperature, Warning, 4-8, 4-15, 6-18
5-50, 6-6, 6-16, 6-17 2972 Field Overload, Shutdown, 4-15, 6-11, 6-31
1469 Speed Hz Match, Shutdown, 4-12, 5-48, 6-10 359 Fail to Start, Shutdown, 4-9, 6-8, 6-19
1471 High AC Current, Shutdown, 4-12, 6-10, 6-28 415 Low Oil Pressure, Shutdown, 4-9, 5-50, 6-7,
1472 High AC Current, Warning, 4-12, 5-46, 6-10, 6-14
6-28 418 Engine Fault, Event, Warning, or Shutdown,
151 High Coolant Temp, 4-9, 5-50, 6-7, 6-17 (Not Displayed), 6-18
1517 Failed Module Shutdown, Warning 4-13 421 Oil Temperature High, Shutdown, 4-9
153, 154, and 155 Engine Fault, Event, Warning, 424 Oil Temperature OOR, Shutdown, 4-10
or Shutdown, 4-9, 6-18 426 Engine Fault, Event, Warning, or Shutdown,
1678 Charger Failure, Warning, 6-11 4-10, 6-18
1689 Clock Not Set, Warning, 4-13, 6-30 427 CAN Datalink Lost, Warning, 6-22
1845 and 1846 Engine Fault, Event, Warning, or 427 CAN Link Lost, Warning, 4-10
Shutdown, 4-12, 6-18 441 Low Battery, Warning, 4-10, 5-42, 6-8, 6-22
1847 High Temperature Fault, Warning, 4-13 442 High Battery, Warning, 4-10, 5-42, 6-8, 6-23
1852 Engine Fault, Event, Warning, or Shutdown, 488 Intake Manifold Temperature High, Shutdown,
4-12, 6-18 4-10
1853, 1854, and 1855 Configurable Annunciator 689 Engine Speed Erratic, Shutdown, 4-10
Fault 3, 4, Warning/Shutdown, 4-12, 6-10 781 CAN Datalink Lost, Shutdown, 4-10, 6-22
1944 Annunciator Output Configuration Error, 5134 Unknown Shutdown at Iidle, Warning, 4-13,
Warning, 4-12, 6-10, 6-29 6-34
195, 196, and 197 Engine Fault, Event, Warning, 5186 Genset Failed to Close, Warning, 4-13, 6-34
or Shutdown, 4-9, 6-18 5187 Utility Failed to Close, Warning, 4-13, 6-34
1965 Exhaust Temperature OOR, Warning, 4-12 5188 Transfer Switch Status Unknown Position,
1992 Engine Fault, Event, Warning, or Shutdown, Warning, 4-13, 6-35
4-12, 6-18 5365 On Secondary Source, Warning, 4-13, 6-35
2118 Low Fuel Pressure, Warning, 4-13, 6-31 Fault Codes
2224 Fuel Level OOR, Warning, 4-13 Reading Using the Control Switch Indicator, 6-2
2335 Loss of AC Sense, Shutdown, 3-41, 3-42, Reading Using the Operator Panel, 6-2
4-13, 6-10, 6-30
234 Overspeed, Shutdown, 3-41, 3-42, 4-9, 5-48, Fault Reset, 2-3
6-7, 6-18 Faults
2398 Ambient Temperature OOR, Warning, 4-13 Alternator Protection, 2-7
B-2
Engine Protection, 2-6 Alternator Startup, 3-28
Genset Protection, 2-6 Gain Tuning, 3-28
Governor, 3-28
G Voltage/Frequency, 3-27
Genset Engine Startup, 3-28
Adjustments
GENERAL INFORMATION
Tuning, 3-27 General Information, 3-2
Glow Plug, 3-38 Harness, 3-17

Governor
Algorithm and Adjustment, 3-39 P
Electronic, 3-38 Parade Rest Mode, 2-7

H R
Harness Remote Emergency Stop, 3-37
Coolant Temperature Sensor, 3-20
Engine, 3-19 Remote Start, 3-37
Genset, 3-18 Run Mode, 2-3
Oil Pressure Sensor, 3-20
Run/Off/Auto Switch, 2-3
Operator Panel, 3-17
Running Mode, 2-7
L
Local Emergency Stop, 3-37
S
Sensor
Local Status Output Indicator, 4-1
Coolant Temperature, 3-20
Oil Pressure, 3-20
M Sensors
Manual Run Mode, 4-2 Coolant Temperature, 3-8
Lube Oil Pressure Switch, 3-9
Module, Control, 2-3
Oil Pressure, 3-8
Mounting Installation, 3-1
Setup, Trims, and Adjustments, 3-22

O Sleep Mode, 2-7, 4-3


Spark Ignition, 3-38
Off Mode, 2-3, 4-2
Operating Modes
Auto Mode, 2-3, 4-2
T
Battle Short, 3-41 Time Delay
Emergency Stop Mode, 4-2 Preheat, 4-2
Manual Run Mode, 4-2 Start, 3-38, 4-2
Off Mode, 2-3, 4-2 Stop, 3-38, 4-2
Run Mode, 2-3
Sleep Mode, 4-3 W
Operator Panel, 2-4
Connections, 2-4 Wiring Diagram, 7-3
Footprint, 3-17 Wiring Information, 3-2

B-3
THIS PAGE INTENTIONALLY LEFT BLANK

B-4
Intentionally Left Blank

58
Cummins Power Generation
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email ask.powergen@cummins.com
www.cumminspower.com
CumminsR, the C logo, and Our energy working for you.
are trademarks of Cummins Inc.
E2014 Cummins Power Generation, Inc. All rights reserved.